Chevrolet - Silverado 2500 4wd - Workshop Manual - 2004 - 2004 (2)

Factory Workshop Manual Make Chevrolet Model Silverado 2500 4wd Engine and year V8-6.6L DSL Turbo VIN 2 (2004) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Description and Operation Accessory Delay Module: Description and Operation RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION SERIAL DATA CONTROL OF RETAINED ACCESSORY POWER (RAP) The class 2 modules receive the power mode message from the body control module (BCM) over the serial data circuits, indicating when the RAP power mode is current. The BCM monitors the ignition switch position, battery condition and passenger compartment doors status to determine whether RAP should be initiated. The modules then support the operation of the systems under their control as required by their RAP power mode operation. RAP will end when one of the following conditions is met: The BCM receives an input indicating the opening of any compartment door. - The BCM internal timer for the RAP expires after approximately 10 minutes. - The BCM detects a decrease in battery capacity below a prescribed limit. The BCM then sends a serial data power mode message Off-Awake ending the RAP function. The class 2 RAP functions are: The power windows - The radio Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accessory Delay Module: Initial Inspection and Diagnostic Overview Diagnostic Starting Point DIAGNOSTIC STARTING POINT Begin the system diagnosis with the Diagnostic System Check - Accessory Delay Module. The diagnostic system check will provide the following information: - The identification of the control modules which command the system - The ability of the control modules to communicate through the serial data circuit - The identification of any stored diagnostic trouble codes DTCs and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check DIAGNOSTIC SYSTEM CHECK TEST DESCRIPTION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9 Steps 1-5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10 Steps 6-7 The numbers below refer to the step numbers on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 3. This step tests for valid system power moding in all ignition switch positions. 5. The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11 Accessory Delay Module: Symptom Related Diagnostic Procedures A Symptoms SYMPTOMS IMPORTANT: Review the system operation in order to familiarize yourself with the system functions. Refer to Retained Accessory Power (RAP) Description and Operation. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the RAP feature. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: - Retained Accessory Power (RAP) On After Timeout - Retained Accessory Power (RAP) Inoperative Steps 1-3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12 Steps 4-5 Steps 1-5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 13 Accessory Delay Module: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Courtesy Lamp Switch: Input showing state of the courtesy lamp as commanded by the BCM. Cargo Door Ajar Switch: Input from the liftgate and liftglass indicating their status. Driver Door Ajar Switch (w/o DDM): Input from the driver door indicating door status. Left Rear/Rear Cargo Door Ajar Switch: Input from the left rear door indicating its status. Passenger Door Ajar Switch (w/o PDM): Input from the front passenger door indicating door status. RAP Relay: Output indicates the RAP Relay state that the control module has commanded. Right Rear Door Ajar Sw.: Input from the right rear door indicating door status. BCM Data List DDM Data List PDM Data List Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 22 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 23 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 24 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 30 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 31 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 32 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 41 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 42 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 43 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 44 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 45 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 46 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 47 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 48 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 49 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 50 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 51 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 52 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 53 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 54 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 55 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 56 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 57 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 58 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 59 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 60 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 61 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 62 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 63 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 64 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 65 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 66 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 67 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 68 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 69 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 70 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 71 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 72 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 73 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 74 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 80 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: Customer Interest OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED > Page 85 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 90 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 95 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 96 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 102 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 111 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 112 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 113 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 114 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 115 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 116 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 117 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 118 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 119 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 120 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 121 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 122 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 123 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 124 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 125 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 126 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 127 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 128 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 129 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 130 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 131 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 132 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 133 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 134 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 135 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 136 Circuit/System Testing Component Testing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 141 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 142 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 143 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 144 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 145 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 146 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 147 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 148 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 149 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 150 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 151 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 152 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 153 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 154 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 155 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 156 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 157 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 158 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 159 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 160 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 161 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 162 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 163 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 164 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 165 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 166 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 167 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 168 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 169 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 170 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 171 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 172 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 173 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 174 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 179 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 180 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 181 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 182 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 183 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 184 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 185 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 186 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 187 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 188 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 189 Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 190 Labor Time Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 195 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: All Technical Service Bulletins OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED > Page 204 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 213 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 218 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 219 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-04-19-001 > Apr > 09 > Drivetrain - Whine or Click Type Noises from Front Axle Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-04-19-001 > Apr > 09 > Drivetrain - Whine or Click Type Noises from Front Axle > Page 225 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 235 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 236 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 237 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 238 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 239 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 240 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 241 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 242 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 243 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 244 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 245 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 246 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 247 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 248 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 249 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 250 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 251 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 252 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 253 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 254 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 255 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 256 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 257 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 258 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 259 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 260 Circuit/System Testing Component Testing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 265 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 266 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 267 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 268 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 269 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 270 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 271 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 272 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 273 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 274 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 275 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 276 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 277 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 278 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 279 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 280 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 281 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 282 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 283 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 284 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 285 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 286 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 287 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 288 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 289 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 290 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 291 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 292 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 293 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 294 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 295 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 296 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 297 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 298 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 303 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 304 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 305 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 306 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 307 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 308 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 309 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 310 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 311 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 312 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 313 Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 314 Labor Time Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 319 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Service and Repair Global Positioning System Module: Service and Repair COMMUNICATION INTERFACE MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The vehicle communication interface module (VCIM) has a specific set of unique numbers that tie the module to each vehicle. These numbers, the 10-digit station identification (STID) and the 11-digit electronic serial number (ESN), are used by the National Cellular Network and Onstar(R) to identify the specific vehicle. Because these numbers are tied to the vehicle identification number of the vehicle, you must never exchange these parts with those of another vehicle. 1. Remove the instrument panel (I/P) top trim panel. 2. Disconnect the wire connectors (2) from the module. 3. Disconnect the coaxial cable (3) from the module. 4. Remove the nuts (2) retaining the module to the bracket. 5. Remove the module (3) from the vehicle. INSTALLATION PROCEDURE 1. If replacing the VCIM, record the 10-digit STID number, and the 11-digit ESN number from the labels on the new module. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Service and Repair > Page 331 2. Install the module on the bracket. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the retaining nuts (2). Tighten Tighten the nuts to 1.6 N.m (14 lb in). 4. Connect the coaxial cable (3) to the module. 5. Connect the wire connectors (2) to the module. 6. Install the I/P trim panel. IMPORTANT: After replacing the vehicle communication interface module, you must reconfigure the Onstar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. In addition, pressing and holding the white dot button on the keypad will NOT reset this version of the Onstar(R) system. This action will cause a DTC to set. 7. Reconfigure the Onstar(R) system. Refer to OnStar Reconfiguration. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 04-08-52-005 > Jun > 04 > Keyless Entry - Inoperative Keyless Entry Module: Customer Interest Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 04-08-52-005 > Jun > 04 > Keyless Entry - Inoperative > Page 340 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 04-08-52-005 > Jun > 04 > Keyless Entry - Inoperative Keyless Entry Module: All Technical Service Bulletins Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 04-08-52-005 > Jun > 04 > Keyless Entry - Inoperative > Page 346 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 355 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 356 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 357 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 363 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 364 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 365 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Locations Door Module: Locations Driver Door Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Page 370 Front Passenger Door Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions Door Module: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 373 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 374 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 375 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 376 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 377 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 378 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 379 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 380 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 381 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 382 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 383 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 384 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 385 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 386 Door Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 387 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 388 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 389 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 390 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 391 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 392 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 393 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 394 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 395 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 396 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 397 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 398 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 399 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 400 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 401 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 402 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 403 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 404 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 405 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 406 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 407 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 408 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 409 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 410 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 411 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 412 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 413 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 414 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 415 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 416 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 417 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 418 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 419 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 420 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 421 Door Module: Connector Views Driver Door Module (DDM) - C1 (With RPO Code YE9) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 422 Driver Door Module (DDM) - C2 (With RPO Code YE9) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 423 Driver Door Module (DDM) - C2 (With RPO Code YE9) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 424 Driver Door Module (DDM) - C3 (With RPO Code YE9) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 425 Driver Door Module (DDM) - C3 (With RPO Code YE9) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 426 Driver Door Module (DDM) - C4 (With RPO Code YE9) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 427 Driver Door Module (DDM) - C4 (With RPO Code YE9) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 428 Driver Door Module (DDM) - C5 (With RPO Code AN3) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 429 Driver Door Module (DDM) - C5 (With RPO Code AN3) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 430 Front Passenger Door Module (FPDM) - C1 (With RPO Code YE9) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 431 Front Passenger Door Module (FPDM) - C2 (With RPO Code YE9) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 432 Front Passenger Door Module (FPDM) - C2 (With RPO Code YE9) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 433 Front Passenger Door Module (FPDM) - C3 (With RPO Code YE9) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 434 Front Passenger Door Module (FPDM) - C3 (With RPO Code YE9) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 435 Front Passenger Door Module (FPDM) - C4 (With RPO Code YE9) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 436 Front Passenger Door Module (FPDM) - C4 (With RPO Code YE9) Part 2 Front Passenger Door Module (FPDM) - C5 (With RPO Code AN3) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 437 Front Passenger Door Module (FPDM) - C5 (With RPO Code AN3) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 438 Door Module: Electrical Diagrams Door Control Module Diagram 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 439 Door Control Module Diagram 2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 440 Door Control Module Diagram 2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 441 Door Control Module Diagram 3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 442 Door Control Module Diagram 3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Page 443 Door Module: Service and Repair DOOR CONTROL MODULE PROGRAMMING AND SETUP Driver Door Module After replacing the driver door module (DDM), perform the programing procedure. Refer to Service Programming System (SPS). See: Testing and Inspection/Programming and Relearning Passenger Door Module After replacing the passenger door module (PDM), perform the following programing and setup procedures: ‹› Service Programming System (SPS). See: Testing and Inspection/Programming and Relearning ‹› Transmitter Programming. See: Testing and Inspection/Programming and Relearning ‹› Control Module Setup. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 04-08-52-005 > Jun > 04 > Keyless Entry - Inoperative Keyless Entry Module: Customer Interest Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 04-08-52-005 > Jun > 04 > Keyless Entry - Inoperative > Page 452 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 04-08-52-005 > Jun > 04 > Keyless Entry - Inoperative Keyless Entry Module: All Technical Service Bulletins Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 04-08-52-005 > Jun > 04 > Keyless Entry - Inoperative > Page 458 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Technical Service Bulletins > Customer Interest for Memory Positioning Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation Memory Positioning Module: Customer Interest Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Technical Service Bulletins > Customer Interest for Memory Positioning Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 467 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Technical Service Bulletins > Customer Interest for Memory Positioning Module: > 04-08-50-003 > Feb > 04 > Interior - Seat Memory Feature Appears Inoperative Memory Positioning Module: Customer Interest Interior - Seat Memory Feature Appears Inoperative Bulletin No.: 04-08-50-003 Date: February 26, 2004 INFORMATION Subject: Enabling Memory Seat Feature via DIC If Feature Appears Inoperative Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon Denali, Yukon Denali XL 2003-2004 HUMMER H2 with Steering Wheel Controls (RPO UK3) (standard on H2) If the memory seat feature appears inoperative, check the Driver Information Center (DIC). Many of the memory seat modules that were returned through the Warranty Parts Center for a condition of inoperative have shown No Trouble Found. The Driver Information Center (DIC), programmed for Seat Entry and Exit, is set to the default "Off" mode at the assembly plant. DO NOT REPLACE THE MEMORY SEAT MODULE. Perform the following procedure. Important: The following procedure will need to be completed for each Remote/Key selection. Using the DIC menu, do the following steps: 1. Set the "Seat Recall" to either "At Key In" or "On Remote" based on the customer's preference. 2. Set the "Exit Seat" to "On". 3. Adjust the following items: Memory Seat: 3.1. Driver's Seat (including the seat back, recliner, lumbar, and side wings) 3.2. Throttle and Brake Pedals (not available on H2 or Silverado and Sierra Trucks) 3.3. Outside Mirrors 3.4. Radio Station Presets 3.5. Last Chosen Climate Control System Settings (not available on Silverado or Sierra Trucks) 3.6. Press and hold the "1" or "2" (for driver 1 or 2) button of the memory control for three seconds. A double chime will sound to let you know that the position has been stored. Easy Exit Seat: 3.1. Press and release the 1 or 2 button or press the unlock button on the desired remote keyless entry transmitter. The seat will move to the stored memory position. 3.2. Adjust the seat to the desired exit position. 3.3. Press and hold the exit button of the memory control (located on the door) for three seconds. A double chime will sound to let you know that the position has been stored for the identified driver (1 or 2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Technical Service Bulletins > Customer Interest for Memory Positioning Module: > 04-08-50-003 > Feb > 04 > Interior - Seat Memory Feature Appears Inoperative > Page 472 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Memory Positioning Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation Memory Positioning Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Memory Positioning Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 478 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Memory Positioning Module: > 04-08-50-003 > Feb > 04 > Interior - Seat Memory Feature Appears Inoperative Memory Positioning Module: All Technical Service Bulletins Interior - Seat Memory Feature Appears Inoperative Bulletin No.: 04-08-50-003 Date: February 26, 2004 INFORMATION Subject: Enabling Memory Seat Feature via DIC If Feature Appears Inoperative Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon Denali, Yukon Denali XL 2003-2004 HUMMER H2 with Steering Wheel Controls (RPO UK3) (standard on H2) If the memory seat feature appears inoperative, check the Driver Information Center (DIC). Many of the memory seat modules that were returned through the Warranty Parts Center for a condition of inoperative have shown No Trouble Found. The Driver Information Center (DIC), programmed for Seat Entry and Exit, is set to the default "Off" mode at the assembly plant. DO NOT REPLACE THE MEMORY SEAT MODULE. Perform the following procedure. Important: The following procedure will need to be completed for each Remote/Key selection. Using the DIC menu, do the following steps: 1. Set the "Seat Recall" to either "At Key In" or "On Remote" based on the customer's preference. 2. Set the "Exit Seat" to "On". 3. Adjust the following items: Memory Seat: 3.1. Driver's Seat (including the seat back, recliner, lumbar, and side wings) 3.2. Throttle and Brake Pedals (not available on H2 or Silverado and Sierra Trucks) 3.3. Outside Mirrors 3.4. Radio Station Presets 3.5. Last Chosen Climate Control System Settings (not available on Silverado or Sierra Trucks) 3.6. Press and hold the "1" or "2" (for driver 1 or 2) button of the memory control for three seconds. A double chime will sound to let you know that the position has been stored. Easy Exit Seat: 3.1. Press and release the 1 or 2 button or press the unlock button on the desired remote keyless entry transmitter. The seat will move to the stored memory position. 3.2. Adjust the seat to the desired exit position. 3.3. Press and hold the exit button of the memory control (located on the door) for three seconds. A double chime will sound to let you know that the position has been stored for the identified driver (1 or 2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Memory Positioning Module: > 04-08-50-003 > Feb > 04 > Interior - Seat Memory Feature Appears Inoperative > Page 483 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Calibration Procedure Memory Positioning Module: Service and Repair Memory Seat Calibration Procedure MEMORY SEAT CALIBRATION PROCEDURE The memory seat module uses position sensor inputs to establish soft stop locations for the adjuster motors several millimeters ahead of the physical limits of the adjuster assembly. After replacing a memory seat module or adjuster components, it may be necessary to reset the adjuster motor soft stop locations. When the repair procedure has been completed, operate the seat adjuster switch in every direction until the seat adjuster reaches its mechanical hard stop by repeatedly pressing and releasing the switch as necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Calibration Procedure > Page 486 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the seat cushion. 2. Disconnect the upper electrical harness connectors (3). 3. Remove the module (2) retaining screws (1). 4. Slide the module to the right to disengage the lower retainers. 5. Disconnect the lower electrical harness connectors (2). 6. Remove the module from the vehicle. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Calibration Procedure > Page 487 1. Position the module into the vehicle. 2. Connect the lower electrical harness connectors (2). 3. Slide the module (2) to the left to engage the lower retainers. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the module retaining screws (3). Tighten Tighten the screws to 3 N.m (26 lb in). 5. Connect the upper electrical harness connectors (3). 6. Install the seat cushion. 7. If a new memory seat module was installed, calibrate the seat. Refer to Memory Seat Calibration Procedure. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation Power Seat Control Module: Customer Interest Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 496 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation Power Seat Control Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 502 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Control Module: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Control Module: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 508 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Control Module: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 509 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Control Module: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 510 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Control Module: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Control Module: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 520 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Control Module: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 521 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Seat Control Module: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 522 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 527 Driver Seat (1 Of 2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 528 Power Seat Control Module: Diagrams Memory Seat Module - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 529 Memory Seat Module - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 530 Memory Seat Module - C3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 531 Memory Seat Module - C3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 532 Memory Seat Module - C3 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 533 Memory Seat Module - C4 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 534 Memory Seat Module - C4 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-50-008 > Aug > 05 > Interior Intermittent Seat Heater Operation Seat Heater Control Module: Customer Interest Interior - Intermittent Seat Heater Operation Bulletin No.: 05-08-50-008 Date: August 19, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-05-008 > Aug > 05 > Interior Heated Seats Intermittently Inoperative Seat Heater Control Module: Customer Interest Interior - Heated Seats Intermittently Inoperative Bulletin No.: 05-08-05-008 Date: August 18, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-08-50-008 > Aug > 05 > Interior - Intermittent Seat Heater Operation Seat Heater Control Module: All Technical Service Bulletins Interior - Intermittent Seat Heater Operation Bulletin No.: 05-08-50-008 Date: August 19, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-08-05-008 > Aug > 05 > Interior - Heated Seats Intermittently Inoperative Seat Heater Control Module: All Technical Service Bulletins Interior - Heated Seats Intermittently Inoperative Bulletin No.: 05-08-05-008 Date: August 18, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Control Module: > 06-08-50-009F > Dec > 10 > Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Control Module: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set Seat Occupant Sensor: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC B0092 Set Bulletin No.: 02-09-41-002A Date: March 24, 2004 TECHNICAL Subject: Air Bag Lamp On, Passenger Air Bag Indicator Always Reads OFF, DTC B0092 Set (Repair Passenger Presence System (PPS) Sensor Harness) Models: 2003-2004 Cadillac Escalade, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon XL with Sensor Indicator Inflatable Restraint Front Passenger/Child Presence Detector (RPO ALO) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 02-09-41-002 (Section 09 - Restraints). Condition Some customers may comment that the Air Bag Lamp is on and the Passenger Air Bag indicator always reads OFF. Upon investigation, the technician may find DTC B0092 set. Cause The cause of this condition may be a shorted Passenger Presence System (PPS) sensor wire. The PPS sensor harness is located under the front passenger seat. This harness may be pinched between the seat frame and the track/riser. Correction Locate the PPS sensor (1) and inspect the harness for proper routing. If the harness is pinched between the seat frame and the track/riser, use the procedure listed below to repair wire(s). 1. Move the front passenger seat to the full rearward and full tilt up position. 2. Loosen the seat frame to track/riser nut and remove the harness. 3. Tighten the seat frame to track/riser nut. 4. Repair any damaged wires. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Control Module: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set > Page 565 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Control Module: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set > Page 575 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 585 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 04-05-25-005A > Sep > 04 > Brakes - ABS Lamp/Service Brake System Message ON Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp/Service Brake System Message ON Bulletin No.: 04-05-25-005A Date: September 28, 2004 ADVANCE SERVICE INFORMATION RESOLUTION Subject: Antilock Brake System (ABS) Light On, Service Brake System Message on Driver Information Center (DIC) (Reprogram Electronic Brake Control Module (EBCM)) Models: 2003-2005 Chevrolet Silverado 2500/3500 HD Series Pickups 2003-2005 GMC Sierra 2500/3500 HD Series Pickups with Identification 2-inch Body Raise, HD Model (RPO HVY) Supercede: This bulletin is being revised to add correction information and additional model years. Please discard Advanced Service Information Bulletin Number 04-05-25-005 (Section 05 - Brakes). Condition Some customers may comment that the ABS light, Service Brake System message comes on intermittently during initial start-up. The condition does not cause a DTC to be stored permanently. Cause The cause may be a timing issue related to the cranking/starting of the vehicles. It appears that the condition is more likely to occur on vehicles with diesel engines, though it can occur on vehicles with gasoline engines as well. Correction Reprogram the EBCM with TIS software version 7.5, released July 26, 2004 or newer. Refer to Service Programming System (SPS). Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 04-05-25-005A > Sep > 04 > Brakes - ABS Lamp/Service Brake System Message ON > Page 590 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 596 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 04-05-25-005A > Sep > 04 > Brakes - ABS Lamp/Service Brake System Message ON Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp/Service Brake System Message ON Bulletin No.: 04-05-25-005A Date: September 28, 2004 ADVANCE SERVICE INFORMATION RESOLUTION Subject: Antilock Brake System (ABS) Light On, Service Brake System Message on Driver Information Center (DIC) (Reprogram Electronic Brake Control Module (EBCM)) Models: 2003-2005 Chevrolet Silverado 2500/3500 HD Series Pickups 2003-2005 GMC Sierra 2500/3500 HD Series Pickups with Identification 2-inch Body Raise, HD Model (RPO HVY) Supercede: This bulletin is being revised to add correction information and additional model years. Please discard Advanced Service Information Bulletin Number 04-05-25-005 (Section 05 - Brakes). Condition Some customers may comment that the ABS light, Service Brake System message comes on intermittently during initial start-up. The condition does not cause a DTC to be stored permanently. Cause The cause may be a timing issue related to the cranking/starting of the vehicles. It appears that the condition is more likely to occur on vehicles with diesel engines, though it can occur on vehicles with gasoline engines as well. Correction Reprogram the EBCM with TIS software version 7.5, released July 26, 2004 or newer. Refer to Service Programming System (SPS). Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 04-05-25-005A > Sep > 04 > Brakes - ABS Lamp/Service Brake System Message ON > Page 601 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 602 Electronic Brake Control Module: Locations ABS Component Views Electronic Brake Control Module (EBCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 603 Electronic Brake Control Module: Diagrams ABS Connector End Views Electronic Brake Control Module (ECBCM) - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 604 Electronic Brake Control Module (ECBCM) - C2 (10/20 Series w/o HP2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 605 Electronic Brake Control Module (ECBCM) - C2 (30 Series and HP2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 606 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. 3. Important: The area around the EHCU MUST be free from loose dirt to prevent contamination of disassembled ABS components. Thoroughly wash all contaminants from around the EHCU. 4. Disconnect the chassis electrical connectors from the EBCM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 607 5. Remove the mounting screws (1) that fasten the EBCM (2) to the BPMV (3). 6. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. Notice: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 608 7. Disconnect the BPMV electrical connector from the EBCM. 8. Clean the BPMV to EBCM mounting surfaces with a clean cloth. Installation Procedure Important: ^ Do not reuse the old mounting screws. Always install new mounting screws with the new EBCM. ^ Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 1. Connect the BPMV electrical connector to the EBCM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 609 2. Install the EBCM to the BPMV. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the new screws (1) in the EBCM (2). ^ Tighten the screws to 5 Nm (39 inch lbs.) in an X-pattern. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 610 4. connect the chassis electrical connectors to the EBCM. 5. Lower the vehicle. 6. Connect the negative battery cable. 7. Revise the tire calibration using the Scan Tool Tire Size Calibration function. 8. Return to Diagnostic Starting Point - Antilock Brake System. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams Cruise Control Module: Diagrams Cruise Control Module (CCM) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Page 615 Cruise Control Module (CCM) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor Relay: > 03-01-38-015A > Oct > 08 > A/C Blower Motor Runs After Vehicle Is Shut OFF Blower Motor Relay: Customer Interest A/C - Blower Motor Runs After Vehicle Is Shut OFF TECHNICAL Bulletin No.: 03-01-38-015A Date: October 27, 2008 Subject: HVAC Blower Motor May Run Continuously After Vehicle is Turned Off (Replace Blower Resistor Relay) Models: 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2004 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon XL with Manual Control HVAC (RPO CJ3) Built Prior to August, 2003 Supercede: This bulletin is being revised to update the parts information. Please discard Corporate Bulletin Number 03-01-38-015 (Section 01 - HVAC). Condition Some customers may comment on the HVAC blower motor running after the vehicle has been turned off. The blower may run for just a few minutes or continuously until the battery is discharged. Cause A new style HVAC blower relay/resistor may stick in the "on" position. When the HVAC fan blower relay has been energized, the contacts may "micro-weld" together. After this occurrence, the HVAC blower may not respond to the HVAC controller commands. Correction Replace the HVAC blower resistor/relay with the type used previous to the 2004 model year. The appropriate part numbers are listed in the table below. For specific repair procedures, refer to the 2004 Service Information (SI) under Blower Motor Resistor Assembly Replacement (SI Document ID # 526350 (C/K) or # 729996 (S/T). Parts Information Warranty Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Relay: > 03-01-38-015A > Oct > 08 > A/C - Blower Motor Runs After Vehicle Is Shut OFF Blower Motor Relay: All Technical Service Bulletins A/C - Blower Motor Runs After Vehicle Is Shut OFF TECHNICAL Bulletin No.: 03-01-38-015A Date: October 27, 2008 Subject: HVAC Blower Motor May Run Continuously After Vehicle is Turned Off (Replace Blower Resistor Relay) Models: 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2004 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon XL with Manual Control HVAC (RPO CJ3) Built Prior to August, 2003 Supercede: This bulletin is being revised to update the parts information. Please discard Corporate Bulletin Number 03-01-38-015 (Section 01 - HVAC). Condition Some customers may comment on the HVAC blower motor running after the vehicle has been turned off. The blower may run for just a few minutes or continuously until the battery is discharged. Cause A new style HVAC blower relay/resistor may stick in the "on" position. When the HVAC fan blower relay has been energized, the contacts may "micro-weld" together. After this occurrence, the HVAC blower may not respond to the HVAC controller commands. Correction Replace the HVAC blower resistor/relay with the type used previous to the 2004 model year. The appropriate part numbers are listed in the table below. For specific repair procedures, refer to the 2004 Service Information (SI) under Blower Motor Resistor Assembly Replacement (SI Document ID # 526350 (C/K) or # 729996 (S/T). Parts Information Warranty Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Service and Repair Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover from the underhood convenience center (1). 2. Remove the compressor relay (2). INSTALLATION PROCEDURE 1. Install the compressor relay (2). 2. Install the cover to the underhood convenience center (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Recalls: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: Recalls Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Recalls: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 641 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Recalls: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 642 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: Customer Interest A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set > Page 648 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 654 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 655 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set > Page 660 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set > Page 666 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 672 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 673 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 674 Control Module HVAC: Locations HVAC Control Module Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 675 Radio (With RPO Code UB7,Y91 Shown, Others Similar) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Manual Control Module HVAC: Diagrams HVAC System - Manual HVAC Control Module - C1 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Manual > Page 678 HVAC Control Module - C1 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Manual > Page 679 HVAC Control Module - C2 Part 1 HVAC Control Module - C2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Manual > Page 680 Control Module HVAC: Diagrams HVAC System - Automatic HVAC Control Module - C1 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Manual > Page 681 HVAC Control Module - C1 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Manual > Page 682 HVAC Control Module - C2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Manual > Page 683 HVAC Control Module - C2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > HVAC System - Manual Control Module HVAC: Description and Operation HVAC System - Manual HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the above features. The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module used for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the above features. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > HVAC System - Manual > Page 686 Control Module HVAC: Description and Operation HVAC System - Automatic HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the above features. HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the above features. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic Control Module HVAC: Service and Repair HVAC System - Automatic Blower Motor Control Processor Replacement BLOWER MOTOR CONTROL PROCESSOR REPLACEMENT REMOVAL PROCEDURE 1. If equipped, remove the sound insulator panel. 2. Disconnect the electrical connector at the blower motor. 3. Disconnect the electrical connector (4) from the blower motor control processor (2). 4. Remove the blower motor control processor retaining screws (3) from the HVAC module (1). 5. Remove the blower motor control processor (2) from the HVAC module (1). INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 689 1. Install the blower motor control processor (2) to the HVAC module (1). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the blower motor control processor retaining screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector (4) to the blower motor control processor (2). 4. Connect the electrical connector at the blower motor. 5. If equipped, install the sound insulator panel. HVAC Control Module Replacement HVAC CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 690 1. Remove the instrument panel accessory trim plate. 2. Remove the screws from the HVAC control module. 3. Depress the control assembly retaining tabs and remove the HVAC control module from the instrument panel. 4. Disconnect the electrical connectors from the HVAC control module. INSTALLATION PROCEDURE IMPORTANT: The Key should be in the off position when connecting the electrical connectors to ensure proper calibration. 1. Connect the electrical connectors to the HVAC control module. 2. Install the HVAC control module into the instrument panel, ensuring that the HVAC control module retaining tabs lock into place. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws from the HVAC control module. Tighten Tighten the screws to 1.9 N.m (17 lb in). 4. Install the instrument panel accessory trim plate IMPORTANT: Do not adjust any controls on the HVAC control module while the HVAC control module is calibrating. If interrupted improper HVAC performance will result. 5. Start the vehicle and let run for one minute. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 691 Control Module HVAC: Service and Repair HVAC System - Manual HVAC CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument cluster trim plate bezel. 2. Remove the instrument panel storage tray. 3. Remove the accessory switch assembly from the instrument panel. 4. Remove the screws from the HVAC control assembly. 5. Remove the HVAC control assembly, with the following procedure: 5.1. Release the retaining tabs. 5.2. Pull the control head out of the instrument panel carrier. 6. Disconnect the electrical connectors from the HVAC control assembly. INSTALLATION PROCEDURE IMPORTANT: The Key should be in the off position when connecting the electrical connectors to ensure proper calibration. 1. Connect the electrical connectors to the HVAC control assembly. 2. Install the HVAC control assembly. 3. Install the accessory switch assembly to the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws from the HVAC control assembly. Tighten Tighten the screws to 1.9 N.m (17 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 692 5. Install the instrument panel storage tray. 6. Install the instrument cluster trim plate bezel. IMPORTANT: Do not adjust any controls on the HVAC control module while the HVAC control module is calibrating. If interrupted improper HVAC performance will result. 7. Start the vehicle and let run for one minute. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Exterior Lighting Relay > Component Information > Diagrams Roof Beacon Relay (With RPO Code 5X7, 5G4, TRW, Or 5Y0) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: Customer Interest Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 706 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 707 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 713 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 714 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P Relay Box: Locations Junction Block - I/P Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 720 Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 721 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 722 Junction Block - I/P Wire Entry Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 723 Junction Block - I/P Wire Entry Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 724 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 725 Relay Box: Locations Relay Block - I/P Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 726 Application Table Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 727 Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 728 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 729 Junction Block - Rear Lamps - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 730 Junction Block - Rear Lamps - C3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 731 Junction Block - Rear Lamps - C4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P Relay Box: Application and ID Junction Block - I/P Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 734 Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 735 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 736 Junction Block - I/P Wire Entry Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 737 Junction Block - I/P Wire Entry Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 738 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 739 Relay Box: Application and ID Relay Block - I/P Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 740 Application Table Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 741 Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 744 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 745 1. Install the engine electrical center bracket assembly to the front fender. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 4 retaining bolts (1). Tighten Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 746 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 747 Relay Box: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolts. Tighten Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 748 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 749 Relay Box: Service and Repair I/P Electrical Center or Junction Block Replacement - Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 750 8. Install the left side end panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 751 Relay Box: Service and Repair I/P Electrical Center or Junction Block Replacement - Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolt. Tighten Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 752 4. Connect the wiring connectors to the fuse block. Refer to Electrical Center Identification Views to ensure the right connections are made. 5. Install the right side end panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 05-02-118-002 > Feb > 05 > Steering - 'Service Rear Wheel Steering' Message Body Control Module: Customer Interest Steering - 'Service Rear Wheel Steering' Message Bulletin No.: 05-02-118-002 Date: February 03, 2005 TECHNICAL Subject: DTC C0455, "Service Rear Wheel Steering", System Jumps from 4-Wheel Steer to 2-Wheel Steer (Reprogram BCM) Models: 2003-2005 Chevrolet Silverado, Suburban 2003-2005 GMC Sierra, Yukon XL with 4-Wheel Steer (RPO NYS) Condition Some customers may comment that the system will jump from 4-wheel steer to 2-wheel steer and the DIC displays the message "Service Rear Wheel Steering". Diagnosis will show DTC C0455-Front Steering Position Sensor malfunction. Cause This condition may be caused by a Class2 communication issue. Correction Reprogram the BCM. 2005 Model Year Vehicles: New software calibration, P/N 15248410, was released on TIS version 12 - broadcast to dealers on December 4, 2004. 2003-2004 Model Year Vehicles: New software calibration, P/N 15259330 ('03 Model Year) and P/N 15259331 ('04 04 Model Year), was released on TIS version 1.75 - broadcast to dealers on January 24, 2005. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 05-02-118-002 > Feb > 05 > Steering - 'Service Rear Wheel Steering' Message Body Control Module: All Technical Service Bulletins Steering - 'Service Rear Wheel Steering' Message Bulletin No.: 05-02-118-002 Date: February 03, 2005 TECHNICAL Subject: DTC C0455, "Service Rear Wheel Steering", System Jumps from 4-Wheel Steer to 2-Wheel Steer (Reprogram BCM) Models: 2003-2005 Chevrolet Silverado, Suburban 2003-2005 GMC Sierra, Yukon XL with 4-Wheel Steer (RPO NYS) Condition Some customers may comment that the system will jump from 4-wheel steer to 2-wheel steer and the DIC displays the message "Service Rear Wheel Steering". Diagnosis will show DTC C0455-Front Steering Position Sensor malfunction. Cause This condition may be caused by a Class2 communication issue. Correction Reprogram the BCM. 2005 Model Year Vehicles: New software calibration, P/N 15248410, was released on TIS version 12 - broadcast to dealers on December 4, 2004. 2003-2004 Model Year Vehicles: New software calibration, P/N 15259330 ('03 Model Year) and P/N 15259331 ('04 04 Model Year), was released on TIS version 1.75 - broadcast to dealers on January 24, 2005. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 768 Body Control Module: Locations Body Control Module (BCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 769 Body Control Module (BCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 772 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 773 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 774 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 775 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 776 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 777 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 778 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 779 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 780 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 781 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 782 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 783 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 784 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 785 Body Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 786 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 787 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 788 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 789 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 790 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 791 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 792 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 793 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 794 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 795 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 796 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 797 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 798 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 799 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 800 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 801 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 802 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 803 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 804 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 805 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 806 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 807 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 808 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 809 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 810 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 811 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 812 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 813 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 814 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 815 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 816 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 817 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 818 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 819 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 820 Body Control Module: Connector Views Body Control Module (BCM) - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 821 Body Control Module (BCM) - C2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 822 Body Control Module (BCM) - C2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 823 Body Control Module (BCM) - C2 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 824 Body Control Module (BCM) - C3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 825 Body Control Module (BCM) - C3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 826 Body Control Module (BCM) - C4 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 827 Body Control Module (BCM) - C4 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 828 Body Control Module (BCM) - C5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 829 Body Control Module (BCM) - C6 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 830 Body Control Module (BCM) - C6 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 831 Body Control Module: Electrical Diagrams Door Control Module Diagram 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 832 Door Control Module Diagram 2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 833 Door Control Module Diagram 2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 834 Door Control Module Diagram 3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 835 Door Control Module Diagram 3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 836 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The body control module (BCM) monitors several inputs in order to arm and disarm the CTD system. The BCM controls the alarm function outputs. When the BCM detects an unauthorized entry (any door opened), the BCM applies ground to the horn, the park lamp and the headlamp relays. The BCM will send messages to the security telltale in the instrument cluster through the Class 2 serial data link. The BCM has the following 8 basic modes for operating the CTD system. The more detailed descriptions are below. - Off state - Idle state - Disarmed state - Ready-to-arm state - Arm initiated state - Arm delay state - Armed state - Alarm state The BCM has the following 6 discrete inputs in order to monitor the CTD system: - Ignition 1 - Driver door latch (door jamb) switch - Passenger door latch (door jamb) switch - Door lock relay - Door key switch - Passenger door unlock relay The BCM applies ground once per second for approximately 2 minutes, or until a valid input to disarm the system is received by the BCM. The Body Control Module (BCM) contains the theft deterrent system logic. The BCM reads the Passlock(TM) data from the Passlock(TM) sensor. If the Passlock(TM) data is correct, the BCM will pass theft. The BCM will then transmit the fuel continue password to the VCM/PCM. During the tamper mode the vehicle may start. The vehicle will then stall. If the BCM receives the wrong Passlock(TM) data, the VTD will immediately go into the tamper mode. The tamper mode will lock-out the vehicle fuel injectors for 10 minutes. The SECURITY indicator will flash while the VTD is in the tamper mode. If the Passlock(TM) sensor sends a correct password to the BCM when the ignition is in the ON position, the BCM will send a fuel enable signal to the VCM/PCM. The VCM/PCM will not disable the fuel due to any BCM message for the remainder of the ignition cycle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION The procedures below are designed to set-up the body control module (BCM) correctly during BCM related service. Before you start, read these procedures carefully and completely. IMPORTANT: The following procedures must be followed: 1. Programming the BCM. 2. Programming Theft Deterrent System Components, if equipped with Passlock System. PROGRAMMING THE BCM IMPORTANT: After the procedure is completed, the personalization settings of the BCM are set to a default setting. Inform the customer that the personalization must be set again. Perform the BCM special function Request BCM Info. for service programming system (SPS), then follow the SPS instructions. Refer to Service Programming System (SPS) in Programming. PROGRAMMING THEFT DETERRENT SYSTEM COMPONENTS IMPORTANT: This procedure has to be performed only for vehicles equipped with Passlock System. Perform the Programming Theft Deterrent System Components in Theft Deterrent after successfully finishing the Setup New BCM procedure. If the Programming Theft Deterrent System Components in the Theft Deterrent procedure is not performed after a BCM replacement, one of the following conditions will occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank or start. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON, with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 839 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable(s). 2. Remove the knee bolster. 3. Disconnect the brown connector. 4. Disconnect all other connectors (1). 5. Remove the BCM from the sliding bracket. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 840 1. Slide the BCM onto the bracket. 2. Connect all the connectors (1) except the brown connector. 3. Connect the brown connector. 4. Install the knee bolster. 5. Connect the negative battery cable(s). 6. Reprogram the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. 7. Perform the Passlock Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 845 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 846 Engine Control Module: Technical Service Bulletins Diesel Engine - Damage Due To Power-Up Devices INFORMATION Bulletin No.: 06-06-01-007F Date: March 31, 2010 Subject: Information On Identifying Duramax(TM) Diesel LB7, LLY, LMM, LBZ Overpower Engine Breakdown or Non-Function Due to Aftermarket Power-Up Devices vs. Non Overpower Engine Non-Function of Pistons, Cylinders, Valvetrain Components and/or Turbocharger DTC P003A Set Models: 2001-2010 Chevrolet Silverado 2003-2009 Chevrolet Kodiak 2006-2010 Chevrolet Express 2001-2010 GMC Sierra 2003-2009 GMC TopKick 2006-2010 GMC Savana Equipped With Duramax(TM) Turbocharged Diesel Engine RPOs LB7, LLY, LMM, LBZ Please Refer to GMVIS Supercede: This bulletin is being revised to add text to the end of the Caution statement. Please discard Corporate Bulletin Number 06-06-01-007E (Section 06 - Engine/Propulsion System). Caution Customers should be informed if a hard part failure is observed in the engine, transmission, transfer case and/or other driveline components, it is likely that powertrain components were weakened to the point of premature failure, while subjected to the higher stresses from Aftermarket Power-Up Devices. Failures associated with the installation of Aftermarket Power-Up Devices, which have been verified, are not covered under the terms of the New Vehicle Warranty. In the majority of these cases, the Fixed Operations Manager (FOM) (in Canada, Warranty Manager) should be contacted and the remaining portion of the powertrain portion of the New Vehicle Warranty blocked. GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage. General Motors Position On Aftermarket Power-Up Devices Important General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. Refer to Service Bulletin Number 04-06-04-054A or newer - Warranty Admin. - Non-GM Parts and Accessories (Aftermarket). Important For further information on aftermarket power-up kits, refer to February 2006 Emerging Issues Course Number 10206.02D. In Canada, information on aftermarket power-up kits was covered in the April 2006 TAC TALK program. Aftermarket power-up devices are non-approved by General Motors. These devices are usually piggy-backed in the main engine harness or remain connected to the diagnostic connector to upload the calibration to the ECM. Recent warranty reviews of returned engines show engine breakdown or non-function due to power-up devices that are utilized for increased horsepower and torque. The following information will assist technicians in identifying overpower engine breakdown or non-function due to aftermarket power-up devices vs. non overpower engine breakdown or non-function. Non-GM parts can alter the design of the vehicle. GM dealers need to be aware of the quality of parts being installed on vehicles. If failure occurs as a result of installation of sub-par parts, warranty coverage may be denied. Refer to Service Bulletin Number 04-06-04-054A or newer Warranty Admin. - Non-GM Parts and Accessories (Aftermarket). Installed Power-Up Kit Aftermarket power-up kits have become a very popular add on for performance-minded customers. These devices can add horsepower and torque and can add additional stress to the engine. These aftermarket calibrations take the Duramax(TM) powertrain outside of its design torque and horsepower rating. They do this by altering air/fuel ratios and injector timing, resulting in excessive cylinder pressure and temperature. When these calibrated parameters are altered, it will upset the design balance and can lead to a reduction of engine life expectancy. Generally, in inspection of Duramax(TM) engine failure due to power-up failures, two or more cylinders will be affected. Installed Power-Up Kit - Once installed, the calibration may mask itself with the factory original calibration ID and may remain the same. Refer to Service Bulletin Number 08-06-04-006F or newer - Information on Identifying Non-GM Calibration Usage for LMM Duramax(TM) Diesel Engine. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 847 - A Tech 2(R) will not positively enable you to identify the use of a power-up device. - Some companies that offer power-up devices claim increases of 150 or more horsepower and 300 or more lb/ft pounds of torque. - A vehicle that is used to the power-up device potential 100% of the time will see earlier engine wear and breakdown. - A vehicle that takes advantage of additional power, but on a less frequent basis, may not see premature engine wear and breakdown until later in the engine's life. - A vehicle not pushed to its limits of the power-up device often may not encounter premature wear and breakdown until after the engine is out of warranty. Duramax(TM) Powertrain Horsepower / Torque Ratings The following horsepower and torque increase over the past years required new internal components to accommodate the increase. - LB7 - 300 hp with 520 ft/lb of torque for model years 2000-2004 - LLY - 310 hp with 605 ft/lb of torque for model years 2004-2008 - LBZ - 360 hp with 650 ft/lb of torque for model year 2006-2008 - LMM - 365 hp with 660 ft/lb of torque for model year 2007-2009 LBZ Improvements To reliably achieve an increase in 50 horsepower with 45 ft/lb torque, the Duramax (TM) diesel had to be revised in many areas. A few of the revisions on the 2006 LBZ were: - New pistons with a revised compression ratio. - Wrist pins that are larger in diameter. - Connecting rods with added material to increase the I section strength. - Engine block and machining changes - Cylinder heads Duramax(TM) Life Expectancy The Duramax(TM) 6.6L V8 Turbo Diesel Engine is sold with a warranty of 100,000 miles/160,000 kilometers. The Duramax(TM) has been tested to survive upwards of 200,000 miles/320,000 kilometers. The Duramax(TM) powertrain is designed for reliability, peak horsepower and torque within its design limits. When a customer installs a power-up device, it drastically reduces the mileage ratings. Important Cylinder Wall Spotting (commonly referred to leopard spots) is from the induction hardening process of the top 1/3 of the cylinder wall. This is normal for the Duramax (TM) Diesel. Identifying Fuel Related Aftermarket Power-Up Devices Aftermarket companies have developed a performance pressure relief fuel valve for Duramax(TM) diesel engines. Refer to above graphic illustration. The performance pressure relief fuel valve attaches to the fuel rail in place of the OEM valve and will not allow any fuel return to the tank, giving 100% of the fuel to be available for additional engine performance. This may cause additional fuel related driveability concerns and may set the following DTCs: - DTC P1093 Fuel Rail Pressure (FRP) Low During Power Enrichment - DTC P0087 Fuel Rail Pressure (FRP) Too Low Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 848 Aftermarket companies have developed a replacement performance/economy fuel injector nozzle. Refer to above illustration. The performance/economy fuel injector nozzles replace the OEM fuel injector nozzles. The aftermarket companies claim increased horsepower, improved fuel atomization, lower exhaust gas temperatures and increase fuel economy. This may cause additional fuel related driveability concerns and may cause internal engine damage to the pistons and fuel injector nozzles. Identifying Overpower Engine Premature Wear and Breakdown When premature wear and breakdown is encountered due to an aftermarket power-up device, it has some very specific characteristics to the internal engine components. The following list will assist in identifying these characteristics as you tear down the engine. - Pistons will be cracked in the lip area, or a hole in the pistons. - Pistons can also be melted on the lip of the combustion bowl, or the top of the pistons can be melted. - Crosshatch will be polished off the cylinder wall in the major thrust face of cylinder below ring belt travel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 849 - Piston pin bore will show signs of scoring, the wrist pins will be discolored, and can have oil coking on them. The connecting rod bushing surface will have accelerated wear. The above illustration shows a connecting rod bushing. - Oil coking on the underside of the piston between the wrist pin bosses. - Signs of bearing fretting will also be noticed on the connecting rod and main bearing caps. Refer to the above illustration for fretting of main bearing cap 1 and back side of connection rod bearing 2. - Excessive heat in engine compartment caused by overpower device. Refer to above illustration (1). Non Overpower Engine Premature Wear and Breakdown The following pictures show results of overheat, overspeed, low/no oil pressure or injector breakdown and how they differ from aftermarket power-up device premature wear and breakdown. Engine Overheat Overheat can be caused by a loss of coolant or a general cooling system failure. Some of the indicators of overheat are: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 850 - Melted pistons. - Head gasket breakdown or non-function. - Warped cylinder heads. - Crankshaft and connecting rod discolored. Engine Overspeed Causes If an engine has been run faster than design capability (redline), and has caused damage as a result, it may be a result of one of the following conditions: - Leaking or failed turbocharger (TC) oil seals. - Oil evident in the intake runners and compressor side of the TC. - Starting fluid use or alternative fuel added to the engine such as ether. Engine Overspeed Results The following are indicators that an overspeed event took place: - Valve train damage. - Pushrods that are bent (4). - Broken valve bridge buttons after cylinder head removal (2). - Rocker arm tip damage (1). - Dry or rusted cylinders from the use of ether, propane or nitrous oxide. - Piston to valve contact. - Cam gear pin shear. Lack of Oil Pressure Lack of lubrication causes rapid bearing wear or bearing to seize. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 851 Bearing failure. Spun main bearings. Engine Premature Wear and Breakdown Due to Improper Function of Fuel Injector A fuel injector may fracture a piston or melt a piston but the damage will be limited to that cylinder only and all other pistons and cylinder walls are OK. In some cases hydraulic lock will occur on the suspected cylinder with an over-fueling fuel injector. Hydraulic lock on the suspected cylinder will cause a bent connecting rod. This can be verified with piston protrusion measurements. 2007-2010 RPO LMM Only Turbocharger DTC P003A Set General Motors has identified a turbocharger (TC) failure mode involving Power-Up Kits that causes soot leakage and DTC P003A to be set. The Power-Up Kits create an overtemperature condition from the increased exhaust gas temperatures that results in a permanent and excessive turbine housing distortion at the TC case halves. 1. A technician may observe one or more of the following conditions: - DTC P003A being set as Current or in History. - An unusual odor emanating from the TC due to an overtemperature condition. - Soot leaking and accumulating at the V-band clamp that secures the TC case halves together. - Limited or unresponsive travel when Commanding the TC Vane Pos. Ctrl. Solenoid ON and OFF with a scan tool. 2. If DTC P003A is found as Current or in History, OR there is evidence of soot leakage (1) in the area of the V-band clamp (1), then technicians MUST verify if the engine control module (ECM) has a Power-Up Kit aftermarket calibration installed or an aftermarket hardware device has been installed. Refer to Service Bulletin Number 08-06-04-006F or newer for the calibration verification information and procedures. How to Handle a Suspect Engine Failure Due to a Power-Up Device Dealers should not automatically decline warranty assistance on engine failures due to the fact that a power-up device or modification is evident or suspected. The technician must identify that the failure is due to a power-up device by teardown analysis and diagnosis of the engine components. The following steps should be taken if an engine failure occurs and it is suspected that the modification or addition of a power-up device maybe the cause of the engine failure. If unclear of this process or direction feel free to contact your Fixed Operations Manager (in Canada, Warranty Manager) for further support. 1. The technician should use proper engine diagnostics to lead him/her to the failed engine components. The Aftermarket Power-Up Kit Check List should be followed and if it is determined that at least three of the Aftermarket Power-Up Kit Check List items match the engine component failures then it can be decided that the failure is not a warrantable claim. 2. Engine failures that meet at least three criteria of the Aftermarket Power-Up Kit Check List are considered failures that are not manufacturer's defects in workmanship or materials. 3. The dealership should contact the PQC, open a case to review the findings and make the final decision on warranty coverage. The Fixed Operations Manager (in Canada, Warranty Manager) should be notified of the PQC decision. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 852 4. Denied claims should be documented as follows: 1. The Aftermarket Power-Up Kit Check List completed with the technicians detailed written findings of the diagnosis on the repair order and retained in the repair order file. 2. Photographs of the failed parts should be retained in the repair order file. 5. The customer should be advised that the failure of their engine was not due to a manufacturer's defect in workmanship or materials and therefore the warranty claim is denied on this failure. Aftermarket Power-Up Kit Check List Important Print and use this aftermarket power-up kit check list when performing an engine disassembly investigation of overpower engine breakdown or non-function. Retain a copy of this checklist and photographs of the failed parts in the repair order file. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 853 LF Of The Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 Engine Control Module: Diagrams Engine Control Module (ECM) - C1 Engine Control Module (ECM) - C1 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 856 Engine Control Module (ECM) - C1 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 857 Engine Control Module (ECM) - C1 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 858 Engine Control Module (ECM) - C1 Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 859 Engine Control Module: Diagrams Engine Control Module (ECM) - C2 Engine Control Module (ECM) - C2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 860 Engine Control Module (ECM) - C2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 861 Engine Control Module (ECM) - C2 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 862 Engine Control Module (ECM) - C2 Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 863 Engine Control Module (ECM) - C2 Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 864 Engine Control Module: Diagrams Engine Control Module (ECM) - C3 Engine Control Module (ECM) - C3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 865 Engine Control Module (ECM) - C3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 866 Engine Control Module (ECM) - C3 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 867 Engine Control Module (ECM) - C3 Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Passlock Function Engine Control Module: Description and Operation Passlock Function VEHICLE/POWERTRAIN CONTROL MODULE The VCM/PCM communicates with the BCM over the Class 2 serial data line. When the BCM determines a no start condition, it sends a Class 2 serial data password to the VCM/PCM in order to disable the fuel injection system. If the BCM receives the expected voltage from the Passlock(TM) sensor, the BCM sends a class 2 serial data password to the VCM/PCM in order to enable the fuel injection system. The VCM/PCM then allows the vehicle to start correctly. If the Class 2 serial data password from the BCM to the VCM/PCM is not within the Vehicle Security Status Message, the fuel injectors will shut OFF during a start attempt. The SECURITY telltale will be illuminated for 10 minutes. If the VCM/PCM does not receive the same password from the BCM as the last learned one, the vehicle will start and then stalls due to the Fuel Lockout. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Passlock Function > Page 870 Engine Control Module: Description and Operation Engine Control Module (ECM) ENGINE CONTROL MODULE (ECM) DESCRIPTION The engine control module (ECM) processes the various input information. The ECM sends the necessary electrical responses to control fuel delivery. The input information has an interrelation to more than one output. One failed input can affect more than one systems operation. Diagnostic System Check - Computers and Control Systems The Diagnostic System Check Computers and Control Systems is an organized approach to identify a problem caused by an electronic engine control system malfunction. This diagnostic check must be the starting point for any driveability complaint diagnosis. The diagnostic directs the technician to the next logical step in diagnosing the complaint. Use the Engine Scan Tool Data Definitions list for a comparison after fulfilling the following items: Complete the Diagnostic System Check-Computers and Control Systems. - Confirm that the on-board diagnostics are functioning properly. - Confirm there are no diagnostic trouble codes. The Engine Scan Tool Definitions are an average of display values recorded from normal operating vehicles. The definitions intend to represent what a normal functioning system should display. IMPORTANT: Do not use a scan tool that displays faulty data. Report the problem to the manufacturer. Using a malfunctioning scan tool can result in misdiagnosis and unnecessary parts replacement. Use only the parameters listed in the Engine Scan Tool Data Definitions for diagnosis. When a scan tool reads other parameters, General Motors recommends not using the values for use in diagnosis. For more description on the values and the use of the scan tool to diagnose the ECM inputs, refer to the applicable diagnostic file. When all the values are within the range illustrated in the Engine Scan Tool Data Definitions, refer to Symptoms - Computers and Control Systems. Control Module Communications The control module system has a computer, the engine control module (ECM), to control fuel delivery, timing, and some emission control systems. The control module system monitors a number of engine and vehicle functions and controls the following operations through the fuel injection control module (FICM): Fuel rail pressure - Fuel injector - Fuel injector pulse width The diesel ECM, located in the engine compartment, is the control center of the control module system. The engine control module used on the electronic fuel injected 6.6L diesel is referred to as a ECM. The ECM constantly looks at the information from various sensors, and controls the systems that affect vehicle performance. The ECM performs the diagnostic function of the system. The ECM can recognize operational problems, alert the driver through the MIL. Service Engine Soon, and store one or more diagnostic trouble codes (DTCs) which identify the problem areas to aid the technician in making repairs. See the specific diagnosis procedure for more information. Malfunction Indicator Lamp (MIL) Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Passlock Function > Page 871 The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Aftermarket (Add-On) Electrical And Vacuum Equipment Any equipment installed on a vehicle after leaving the factory that connects to the electrical or vacuum systems of the vehicle defines aftermarket (Add-On) electrical and vacuum equipment. The vehicle design makes no allowances for this type of equipment. NOTE: - Do not attach add-on vacuum operated equipment to this vehicle. The use of add-on vacuum equipment may result in damage to vehicle components or systems. - Connect any add-on electrically operated equipment to the vehicle's electrical system at the battery (power and ground) in order to prevent damage to the vehicle. The add-on electrical equipment, even when installed to these strict guidelines, may still cause the powertrain system to malfunction. This may also include any equipment which is not connected to the electrical system of the vehicle such as portable telephones and radios. Therefore, the first step in diagnosing any powertrain problem is to eliminate all of the aftermarket electrical equipment from the vehicle. After this is done, if the problem still exists, diagnose the problem in the normal manner. Computers and Control Systems Information The driveability and emissions information describes the function and operation of the control module. The emphasis is placed on the diagnosis and repair of problems related to the system. Engine Components, Wiring Diagrams, and Diagnostic Trouble Code (DTC) tables: The Component Locations - The Wiring Diagrams - The Control Module Terminal End View and Terminal Definitions - The Diagnostic System Check - Computers and Control Systems - The Diagnostic Trouble Code (DTC) tables The Component System includes the following items: The component and circuit description - The On-vehicle service for each subsystem - The Functional checks with the diagnostic tables - How To Use Electrical Systems Diagnostic Information The DTCs also contain the diagnostic support information containing the circuit or the system information, and helpful diagnostic information. Wiring Harness Service The control module harness electrically connects the control module to the various solenoids, switches, and sensors in the vehicle engine compartment and passenger compartment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Passlock Function > Page 872 Replace the wire harnesses with the proper part number replacement. When splicing signal wires into a harness, use the wiring that has high temperature insulation. Consider the low amperage and voltage levels utilized in the powertrain control systems. Make the best possible bond at all splices. Use rosin-core solder in these areas. Molded-on connectors require complete replacement of the connector. Splice a new connector into the harness. Replacement connectors and terminals are listed in Group 8.965 in the Standard Parts Catalog. Connectors and Terminals In order to prevent shorting between opposite terminals, use care when probing a connector and when replacing terminals. Damage to the components could result. Always use jumper wires between connectors for circuit checking. Never probe through the Weather-Pack seals. The J 35616-B Connector Test Adapter Kit , or the equivalent, contains an assortment of flexible connectors used in order to probe the terminals during the diagnosis. The fuse remover and the BT-8616 Test Tool, or the equivalent, is used for removing a fuse and to adapt the fuse holder to a meter for diagnosis. Open circuits are often difficult to locate by sight because oxidation or terminal misalignment are hidden by the connectors. Merely wiggling a connector on a sensor or in the wiring harness may temporarily correct the open circuit. Oxidized or loose connections may cause intermittent problems. Be certain the type of connector and terminal before making any connector or terminal repair. Weather-Pack and Com-Pack III terminals look similar, but are serviced differently. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Passlock Function > Page 873 Engine Control Module: Description and Operation Turbocharger ENGINE CONTROL MODULE (ECM) The ECM controls all turbocharger control functions. The ECM monitors information from various sensor inputs that include the following: - The accelerator pedal position (APP) sensor - The engine coolant temperature (ECT) sensor - The mass airflow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The boost pressure sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 874 Engine Control Module: Service and Repair ENGINE CONTROL MODULE (ECM) REPLACEMENT Service of the engine control module (ECM) should consist of either replacement of the ECM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the ECM to be replaced, the replacement ECM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty ECM and install the new service ECM. REMOVAL PROCEDURE IMPORTANT: - To prevent internal ECM damage, the ignition switch must be OFF when disconnecting or connecting power to the ECM. - Remove any debris from the ECM connector surfaces before servicing the ECM. Inspect the ECM module connector gaskets when diagnosing or replacing the ECM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the ECM. - The replacement ECM must programmed. - It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100%. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5000km (3,000 mi) from the last engine oil change. 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 2. Disconnect the negative battery cable. 3. Disconnect the ECM electrical connectors (2). 4. Release the ECM cover retaining tabs. 5. Remove the ECM cover from the bracket. 6. Remove the ECM cover. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 875 1. Install the ECM. IMPORTANT: The cover must be fully installed prior to the electrical connections being made to ensure the ECM is fully seated in the bracket. 2. Install the ECM cover to the bracket. 3. Engage the ECM cover retaining tabs. 4. Connect the ECM electrical connectors (2). 5. Connect the negative battery cable. 6. If a NEW ECM was installed, program the ECM. Refer to Service Programming System (SPS) in Programming. See: Testing and Inspection/Programming and Relearning 7. Perform the turbocharger learn procedure. Refer to Turbocharger Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations FUEL PUMP RELAY - SECONDARY (Vehicles with Dual Tanks Only) Fuel Pump Relay-Secondary-With Dual Tanks The Fuel Pump Relay - Secondary is attached to the Underhood Fuse Block Bracket. The Underhood Fuse Block is located at the left side of the engine compartment, to the rear of the battery. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection Ignition Relay: Testing and Inspection IGNITION RELAY DIAGNOSIS CIRCUIT DESCRIPTION The EDU/IGN 1 relay is normally an open relay. The relay armature is held in the open position by spring tension. When the ignition switch is turned to the Run or Start position, current will flow through the relay coil. A wire connected to the other end of the relay coil completes the path to ground through the engine control module (ECM). The electromagnetic field created by the relay coil overcomes the spring tension and moves the armature, allowing the contacts to close. The closed relay contacts allow current to flow from the battery to the following fuses: The ECM RPV fuse - The EDU fuse When the ignition switch is turned to the OFF position, the electromagnetic field collapses. This action allows the spring tension to move the armature away from the relay contacts, which interrupts current flow to the fuses. If the EDU/IGN 1 relay fails to close, the engine will crank but will not run. The class 2 communications will be available with the use of a scan tool. The EDU/IGN 1 relay table assumes that the vehicle battery is fully charged. TEST Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 884 Steps 1-4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 885 Steps 5-7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 886 Steps 8-11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 887 Steps 12-14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 888 Steps 15-17 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 889 Steps 18-22 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 890 Steps 23-25 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations Below Driver Seat - Restraint Systems Wiring Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 895 Inflatable Restraint Sensing And Diagnostic Module: Diagrams Inflatable Restraint Sensing and Diagnostic Module (SDM) - Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 896 Inflatable Restraint Sensing and Diagnostic Module (SDM) - Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 897 Inflatable Restraint Sensing and Diagnostic Module (SDM) - Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 898 Inflatable Restraint Sensing And Diagnostic Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The sensing and diagnostic module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at various locations on the vehicle. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors. The SDM compares the results of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and requests the instrument panel cluster (IPC) to turn the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will request the IPC to turn the AIR BAG indicator ON. In the event that ignition 1 voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important to note, when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 899 Inflatable Restraint Sensing And Diagnostic Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 7. 2. Remove the drivers seat. 3. Remove the driver side door sill plate. 4. Fold back the carpet to access the inflatable restraint sensing and diagnostic module (SDM). 5. Remove the connector position assurance (CPA) (1) from the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the open position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 900 7. Disconnect the SDM wiring harness connector (1) from the SDM (3). 8. Remove the SDM mounting fasteners. 9. Remove the SDM from the vehicle. IMPORTANT: The following repair procedures should only be used in the event that the inflatable restraint sensing and diagnostic module (SDM) mounting studs and/or fasteners are damaged to the extent that the SDM may no longer be properly mounted. 10. Repair the fasteners using the following procedure: 10.1. Remove the stripped nut and discard the nut. 10.2. Drill out the weld spots to the weld stud from the floor pan side, then remove and discard the stud. 10.3. Condition the floor panel attaching surface where the new stud is to be installed. 10.4. Install new weld stud GM P/N 115115602 and clamp the weld stud. 10.5. Migweld the stud at the drilled holes from above or below the floor pan, as required. 10.6. Apply body sealer GM P/N 9984248 around any exposed openings. 10.7. Install a new fastener GM P/N 11515933. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other contaminants from the mounting surface. 2. Install the SDM (3) horizontally to the vehicle. 3. Point the arrow on the SDM toward the front of the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the SDM mounting fasteners. Tighten Tighten fasteners to 10 N.m (89 lb in). 5. Connect the SDM wiring harness connector (1) to the SDM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 901 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the close position. 7. Install the connector position assurance (CPA) (1) to the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 8. Position the carpet to cover the inflatable restraint sensing and diagnostic module (SDM). 9. Install the door sill plate. 10. Install the driver seat. IMPORTANT: The AIR BAG indicator may remain ON after the SDM has been replaced. DTC B1001 may set requiring the SDM part number to be set in multiple modules. If the indicator remains ON after enabling the SIR system, perform the diagnostic system check and follow the steps thoroughly to ensure that the SDM is set properly. 11. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 7. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement Steering Control Module: Service and Repair Rear Wheel Steering Control Module Bracket Replacement Rear Wheel Steering Control Module Bracket Replacement Removal Procedure 1. Remove the rear wheel steering control module from the bracket. 2. Remove the bolts retaining the bracket (2) to the frame. 3. Remove the bracket (2) from the vehicle. Installation Procedure 1. Install the bracket (2) to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts retaining the bracket (2) to the frame. ^ Tighten the bracket retaining bolts to 10 Nm (81 inch lbs.). 3. Install the rear wheel steering control module to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement > Page 908 Steering Control Module: Service and Repair Rear Wheel Steering Control Module Replacement Rear Wheel Steering Control Module Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the spare tire from the vehicle to gain access to the control module. 3. Disconnect the electrical connectors from the control module. 4. Remove the bolts (1) retaining the control module (2) to the bracket. 5. Remove the control module from the vehicle. Installation Procedure 1. Install the control module to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the control module (2) retaining bolts (1). ^ Tighten the bolts to 24 Nm (18 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement > Page 909 3. Connect the electrical connectors to the module. 4. Program the control module. Refer to Service Programming System (SPS) in Programming. 5. Install the spare tire to the vehicle. 6. Lower the vehicle. 7. Perform a learn alignment. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Transmission Control Module Replacement Control Module: Service and Repair Transmission Control Module Replacement Transmission Control Module (TCM) Replacement Removal Procedure Important: ^ Remove any debris from the transmission control module(TCM) connector surfaces before servicing the TCM. Inspect the TCM module connector gaskets when diagnosing or replacing the TCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the TCM. ^ The ignition must be OFF when disconnecting or reconnecting power to the TCM. 1. Disconnect the negative battery cable. 2. Remove the TCM cover bolts (1) located on the left side of the radiator shroud. 3. Pull the cover and TCM up and away from the radiator shroud. 4. Push up on the retainers (1) in order to remove the TCM from the cover. 5. Disconnect the TCM electrical connectors (2) and remove the TCM from the vehicle. Installation Procedure 1. Connect the TCM electrical connectors (2) to the TCM. 2. Install the TCM to the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Transmission Control Module Replacement > Page 925 3. Using the alignment tabs (1), install the cover and module to the radiator shroud. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the TCM cover bolts (1) to the radiator shroud. ^ Tighten the bolts to 9 Nm (80 inch lbs.). 5. Connect the negative battery cable. 6. Reprogram the TCM. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Transmission Control Module Replacement > Page 926 Control Module: Service and Repair Transmission Control Module Reprogramming Procedures Transmission Control Module Reprogramming Procedures Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install new module before proceeding. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the Electronic Control Unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to Program/Reprogram. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Reconnect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the Electronic Control Unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to Program/Reprogram. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 02-04-21-006E > Jul > 06 > AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: Customer Interest AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 02-04-21-006E > Jul > 06 > AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 > Page 936 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 02-04-21-006E > Jul > 06 > AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: All Technical Service Bulletins AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 02-04-21-006E > Jul > 06 > AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 > Page 942 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 05-04-21-002 > Mar > 05 > Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 05-04-21-002 > Mar > 05 > Drivetrain - Transfer Case Control Module Replacement > Page 947 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 05-04-21-002 > Mar > 05 > Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 05-04-21-002 > Mar > 05 > Drivetrain - Transfer Case Control Module Replacement > Page 953 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > NVG 246-NP8 Control Module: Locations NVG 246-NP8 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > NVG 246-NP8 > Page 956 Control Module: Locations NVG 263-NP1 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 957 Control Module: Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 958 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 959 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 Control Module: Service and Repair NVG 246-NP8 Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install new module before proceeding. Before reprogramming close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to do so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Disconnect the scan tool from the vehicle and connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to Program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Reconnect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 962 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 963 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 964 Control Module: Service and Repair NVG 263-NP1 Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 965 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install a new module before proceeding. Before reprogramming, close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to do so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 966 Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information about the type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Connect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information about the type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 972 Passlock Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 973 Lock Cylinder Switch: Description and Operation PASSLOCK(TM) SENSOR The Passlock(TM) sensor is inside the ignition cylinder lock housing. The Passlock(TM) sensor contains 2 hall effect sensors. The tamper hall effect sensor is on the top. The security hall effect sensor is under the tamper hall effect sensor. Both of the hall effect sensors monitor the magnet of the lock cylinder through an opening. The tamper hall effect sensor is physically placed on top of the security hall effect sensor. This arrangement enables the tamper hall effect sensor to engage first if an intruder attempts to bypass the Passlock(TM) sensor by placing a large magnet around that area of the steering column. There is a tamper resistor inside the Passlock(TM) sensor in order to help prevent tamper to the system. Passlock(TM) equipped vehicles have a selection of 10 different security resistors ranging from 0.5K ohms up to 13.6K ohms. Installing one of the security resistors inside the Passlock(TM) sensor will generate a unique Passlock(TM) code. All 10 combinations of the Passlock(TM) sensor have the same part number. However, you cannot simply replace the Passlock(TM) sensor and expect the system to operate properly. Always start by performing the Diagnostic System Check first and following the instructions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Description and Operation Pedal Positioning Switch: Description and Operation Brake Pedal Position Sensor Calibration Description and Operation Calibration Criteria The brake pedal position (BPP) sensor receives a low reference signal and a 5-volt reference signal from the electro-hydraulic power steering (EHPS). Whenever the brake pedal is applied, the brake pedal position sensor applies a variable voltage signal to the EHPS through the BPP sensor signal circuit. Brake pedal position sensor calibration must be performed after the brake pedal position sensor or EHPS system have been serviced. The calibration procedure will set brake pedal position sensor home value. This value is used by the EHPS to determine the brake pedal position and the brake pedal rate. These two outputs are provided to the hybrid control module (HCM) via GMLAN. Calibration Procedure 1. Install a scan tool. 2. Turn ON the ignition, with the engine OFF. 3. Important: Make sure the brake pedal is not depressed before sending BPP sensor calibration command. Navigate to the Special Functions screen on the scan tool and select BPP Sensor Calibration in order to perform the brake pedal position sensor calibration. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Description and Operation > Page 977 Pedal Positioning Switch: Service and Repair Brake Pedal Position Sensor Replacement Removal Procedure 1. Important: Once the Brake Pedal Position Sensor bolt is removed for any reason, a new 4 mm bolt, with fresh LOCTITETM will need to be installed. Remove the brake pedal position sensor bolt (1). 2. Remove the brake pedal position sensor (2) from the mounting bracket. 3. Disconnect the brake pedal position sensor electrical connector (1). 4. Remove the brake pedal position sensor (2) from the vehicle Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Description and Operation > Page 978 1. Connect the brake pedal position sensor (2) electrical connector (1). 2. Align the brake pedal position sensor (1) with the actuation arm (2) on the brake pedal and the brake pedal position sensor mounting bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Description and Operation > Page 979 3. Notice: Refer to Fastener Notice in Service Precautions. Install a new 4 mm bolt (1), with LOCTITETM , to the brake pedal position sensor. ^ Tighten the bolt to 9 Nm (80 inch lbs.). 4. Calibrate the brake pedal position sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Diagrams Door Latch Assembly (Key Cylinder Switch) - Driver C3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Description and Operation Pedal Positioning Switch: Description and Operation Brake Pedal Position Sensor Calibration Description and Operation Calibration Criteria The brake pedal position (BPP) sensor receives a low reference signal and a 5-volt reference signal from the electro-hydraulic power steering (EHPS). Whenever the brake pedal is applied, the brake pedal position sensor applies a variable voltage signal to the EHPS through the BPP sensor signal circuit. Brake pedal position sensor calibration must be performed after the brake pedal position sensor or EHPS system have been serviced. The calibration procedure will set brake pedal position sensor home value. This value is used by the EHPS to determine the brake pedal position and the brake pedal rate. These two outputs are provided to the hybrid control module (HCM) via GMLAN. Calibration Procedure 1. Install a scan tool. 2. Turn ON the ignition, with the engine OFF. 3. Important: Make sure the brake pedal is not depressed before sending BPP sensor calibration command. Navigate to the Special Functions screen on the scan tool and select BPP Sensor Calibration in order to perform the brake pedal position sensor calibration. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Description and Operation > Page 991 Pedal Positioning Switch: Service and Repair Brake Pedal Position Sensor Replacement Removal Procedure 1. Important: Once the Brake Pedal Position Sensor bolt is removed for any reason, a new 4 mm bolt, with fresh LOCTITETM will need to be installed. Remove the brake pedal position sensor bolt (1). 2. Remove the brake pedal position sensor (2) from the mounting bracket. 3. Disconnect the brake pedal position sensor electrical connector (1). 4. Remove the brake pedal position sensor (2) from the vehicle Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Description and Operation > Page 992 1. Connect the brake pedal position sensor (2) electrical connector (1). 2. Align the brake pedal position sensor (1) with the actuation arm (2) on the brake pedal and the brake pedal position sensor mounting bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Description and Operation > Page 993 3. Notice: Refer to Fastener Notice in Service Precautions. Install a new 4 mm bolt (1), with LOCTITETM , to the brake pedal position sensor. ^ Tighten the bolt to 9 Nm (80 inch lbs.). 4. Calibrate the brake pedal position sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Door Lock Switch - Driver (Base Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 997 Door Lock Switch - Front Passenger (Base Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures Power Door Lock Switch: Procedures Switch Replacement - Door Lock and Side Window - Driver SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - DRIVER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 1000 6. Remove the door module from the switch panel bezel. INSTALLATION PROCEDURE 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten Tighten the screw to 2 N.m (18 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 1001 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Switch Replacement - Door Lock and Side Window - Passenger SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - PASSENGER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 1002 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. INSTALLATION PROCEDURE 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 1003 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 1004 Power Door Lock Switch: Removal and Replacement Switch Replacement - Door Lock and Side Window - Driver Switch Replacement - Door Lock and Side Window - Driver Removal Procedure 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 1005 Installation Procedure 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. See: Testing and Inspection/Programming and Relearning Switch Replacement - Door Lock and Side Window - Passenger Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 1006 Switch Replacement - Door Lock and Side Window - Passenger Removal Procedure 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 1007 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS). See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 1012 Seat Lumbar Motor/Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 1013 Seat Front Vertical Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 1014 Seat Horizontal Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 1015 Power Seat Motor Position Sensor: Diagrams Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 1016 Seat Lumbar Motor/Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 1017 Seat Front Vertical Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 1018 Seat Horizontal Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 1019 Seat Rear Vertical Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 1020 Seat Recliner Motor Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing Power Seat Switch: Customer Interest Interior - Power Seat Switch Knobs Loose/Missing Bulletin No.: 05-08-50-017 Date: December 14, 2005 TECHNICAL Subject: Power Front Seat (RPO AN3) Switch Knobs Loose or Missing (Replace Switch Knobs) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2006 GMC Sierra, Yukon, Yukon XL with Individual Front Seat Non-Bucket (RPO AN3) and Driver Front Seat Power Adjuster (AG1) and/or Passenger Front Seat Power Adjuster (AG2) Condition Some customers may comment that the power front seat adjuster switch knobs are loose and fall off or are missing. Correction Replace the front seat adjuster switch knob. These knobs were formerly available only as part of the power seat adjuster switch. DO NOT replace the switch if the knob only needs to be replaced. Parts Information Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing > Page 1029 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing Power Seat Switch: All Technical Service Bulletins Interior - Power Seat Switch Knobs Loose/Missing Bulletin No.: 05-08-50-017 Date: December 14, 2005 TECHNICAL Subject: Power Front Seat (RPO AN3) Switch Knobs Loose or Missing (Replace Switch Knobs) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2006 GMC Sierra, Yukon, Yukon XL with Individual Front Seat Non-Bucket (RPO AN3) and Driver Front Seat Power Adjuster (AG1) and/or Passenger Front Seat Power Adjuster (AG2) Condition Some customers may comment that the power front seat adjuster switch knobs are loose and fall off or are missing. Correction Replace the front seat adjuster switch knob. These knobs were formerly available only as part of the power seat adjuster switch. DO NOT replace the switch if the knob only needs to be replaced. Parts Information Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing > Page 1035 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 1036 Power Seat Switch: Locations Driver Seat (1 Of 2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 1037 Front Passenger Seat (1 Of 2) (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 1038 Power Seat Switch: Diagrams Seat Adjuster Switch - Driver (With RPO Code AN3) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 1039 Seat Adjuster Switch - Driver (With RPO Code AN3) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 1040 Seat Adjuster Switch - Driver (AG1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 1041 Seat Adjuster Switch- Front Passenger (With RPO Code AN3) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 1042 Seat Adjuster Switch- Front Passenger (With RPO Code AN3) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 1043 Seat Bolster/Lumbar Switch - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 1044 Seat Bolster/Lumbar Switch - Front Passenger (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures Power Seat Switch: Procedures Lumbar Switch Replacement LUMBAR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the power seat switch bezel containing the lumbar switch (1) from the seat. 2. Remove the lumbar switch screws from the power seat switch bezel. 3. Remove the lumbar switch. INSTALLATION PROCEDURE 1. Install the lumbar switch to the power seat switch bezel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the lumbar switch screws. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the power seat switch bezel (1) to the seat. Seat Switch Bezel Replacement SEAT SWITCH BEZEL REPLACEMENT REMOVAL PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 1047 1. Remove the screws retaining the power seat switch bezel. 2. Disconnect the electrical connectors. 3. Remove the lumbar support switch. 4. Remove the power seat adjuster switch assembly. INSTALLATION PROCEDURE 1. Install the power seat adjuster switch assembly to the seat switch bezel. 2. Install the lumbar support switch to the seat switch bezel. 3. Connect the electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws retaining the power seat switch bezel. Tighten Tighten the screws to 2 N.m (18 lb in). Seat Switch Replacement - Power SEAT SWITCH REPLACEMENT - POWER REMOVAL PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 1048 1. Remove the power seat switch bezel from the seat. 2. Remove the power seat switch to bezel screws. 3. Remove the power seat switch. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the power seat switch to bezel screws. Tighten Tighten the screws to 2 N.m (18 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 1049 2. Install the power seat switch bezel to the seat. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 1050 Power Seat Switch: Removal and Replacement Seat Switch Replacement - Power Removal Procedure 1. Remove the power seat switch bezel from the seat. 2. Remove the power seat switch to bezel screws. 3. Remove the power seat switch. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the power seat switch to bezel screws. Tighten the screws to 2 N.m (18 lb in). 2. Install the power seat switch bezel to the seat. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-50-007 > Mar > 04 > Interior - Front Heated Seat(s) Inoperative Seat Heater Switch: Customer Interest Interior - Front Heated Seat(s) Inoperative Bulletin No.: 04-08-50-007 Date: March 12, 2004 INFORMATION Subject: Service Information for Front Heated Seat Inoperative/Cold Models: 2003-2004 Cadillac Escalade/ESV/EXT 2003-2004 Chevrolet Avalanch/Silverado/Suburban/Tahoe 2003-2004 GMC Denali/Sierra/Yukon/Yukon XL 2003-2004 Hummer H2 The purpose of this bulletin is to provide the technician with the following service information: ^ Heated Seats Switch Operation ^ Heated Seats Switch Diagnostics ^ Heated Seats Switch Customer Information Switch Operation 1. The engine must be running for the heated seat feature to work. The heated seats will shut off automatically when the ignition is turned off. 2. Two buttons, located on the door, are used to control the heated seat. ^ Press the horizontal (RH) button to heat the entire seat, back and cushion. ^ Press the vertical (LH) button to heat ONLY the seat back. ^ The three light bars are an indicator of the level of heat selected for either the entire seat (horizontal button) or ONLY the seat back (vertical button). 3. To heat both the seat back and seat cushion at the same time, press the horizontal (RH) button with the heated seat symbol one time. ^ All 3 light bars will glow indicating the HIGH temperature setting. ^ The horizontal (RH) button does NOT have an ON/OFF indicator light. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-50-007 > Mar > 04 > Interior - Front Heated Seat(s) Inoperative > Page 1059 4. Press the button a second time, 2 light bars will glow indicating the MEDIUM temperature setting for the entire seat. 5. Press the button a third time, 1 light bar will glow indicating the LOW temperature setting for the entire seat. 6. Press the button a fourth time to turn the entire heated seat OFF. 7. To heat ONLY the seat back, press the vertical (LH) button one time. ^ An ON/OFF indicator light over the heated seat back symbol will glow to designate that ONLY the seat back is being heated. ^ All 3 light bars over the horizontal (RH) button will glow indicating the HIGH temperature setting for ONLY the seat back. 8. Press the button a second time, 2 light bars will glow indicating the MEDIUM temperature setting for ONLY the seat back. 9. Press the button a third time, 1 light bar will glow indicating the LOW temperature setting for ONLY the seat back. 10. Press the button a fourth time to turn the heated seat back OFF. Switch Diagnostics Important: In order to eliminate unnecessary part replacement and comeback repairs, it is essential that the appropriate diagnostic tables and aids found in the applicable manuals are followed. 1. Verify the condition prior to making any repairs. Refer to Seats and Seat Controls in the applicable Owners Manual or this bulletin for proper heated seat switch operation information. 2. If an improperly operating front heated seat condition exists, refer to the Diagnostic Information and Procedures in the Seats sub-section of the applicable Service Manual in order to diagnose the system accurately. 3. When measuring the resistance of the seat heater elements, ensure the values are within the updated range of 1.5-5.5 ohms. Refer to DTC B2425 or B2430-Clearing the DTC in the Diagnostic Information and Procedures in the Seats sub-section of the applicable Service Manual. Customer Information Some heated seat components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) for heat function not operating properly. Analyses of these parts show 'no out of specification condition' or No Trouble Found (NTF). 1. Provide customers with the knowledge that if bumped, either one of the heated seat switches can be activated/deactivated accidentally. 2. Ensure customers have a thorough understanding of how the heated seat switches function. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-50-007 > Mar > 04 > Interior - Front Heated Seat(s) Inoperative Seat Heater Switch: All Technical Service Bulletins Interior - Front Heated Seat(s) Inoperative Bulletin No.: 04-08-50-007 Date: March 12, 2004 INFORMATION Subject: Service Information for Front Heated Seat Inoperative/Cold Models: 2003-2004 Cadillac Escalade/ESV/EXT 2003-2004 Chevrolet Avalanch/Silverado/Suburban/Tahoe 2003-2004 GMC Denali/Sierra/Yukon/Yukon XL 2003-2004 Hummer H2 The purpose of this bulletin is to provide the technician with the following service information: ^ Heated Seats Switch Operation ^ Heated Seats Switch Diagnostics ^ Heated Seats Switch Customer Information Switch Operation 1. The engine must be running for the heated seat feature to work. The heated seats will shut off automatically when the ignition is turned off. 2. Two buttons, located on the door, are used to control the heated seat. ^ Press the horizontal (RH) button to heat the entire seat, back and cushion. ^ Press the vertical (LH) button to heat ONLY the seat back. ^ The three light bars are an indicator of the level of heat selected for either the entire seat (horizontal button) or ONLY the seat back (vertical button). 3. To heat both the seat back and seat cushion at the same time, press the horizontal (RH) button with the heated seat symbol one time. ^ All 3 light bars will glow indicating the HIGH temperature setting. ^ The horizontal (RH) button does NOT have an ON/OFF indicator light. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-50-007 > Mar > 04 > Interior - Front Heated Seat(s) Inoperative > Page 1065 4. Press the button a second time, 2 light bars will glow indicating the MEDIUM temperature setting for the entire seat. 5. Press the button a third time, 1 light bar will glow indicating the LOW temperature setting for the entire seat. 6. Press the button a fourth time to turn the entire heated seat OFF. 7. To heat ONLY the seat back, press the vertical (LH) button one time. ^ An ON/OFF indicator light over the heated seat back symbol will glow to designate that ONLY the seat back is being heated. ^ All 3 light bars over the horizontal (RH) button will glow indicating the HIGH temperature setting for ONLY the seat back. 8. Press the button a second time, 2 light bars will glow indicating the MEDIUM temperature setting for ONLY the seat back. 9. Press the button a third time, 1 light bar will glow indicating the LOW temperature setting for ONLY the seat back. 10. Press the button a fourth time to turn the heated seat back OFF. Switch Diagnostics Important: In order to eliminate unnecessary part replacement and comeback repairs, it is essential that the appropriate diagnostic tables and aids found in the applicable manuals are followed. 1. Verify the condition prior to making any repairs. Refer to Seats and Seat Controls in the applicable Owners Manual or this bulletin for proper heated seat switch operation information. 2. If an improperly operating front heated seat condition exists, refer to the Diagnostic Information and Procedures in the Seats sub-section of the applicable Service Manual in order to diagnose the system accurately. 3. When measuring the resistance of the seat heater elements, ensure the values are within the updated range of 1.5-5.5 ohms. Refer to DTC B2425 or B2430-Clearing the DTC in the Diagnostic Information and Procedures in the Seats sub-section of the applicable Service Manual. Customer Information Some heated seat components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) for heat function not operating properly. Analyses of these parts show 'no out of specification condition' or No Trouble Found (NTF). 1. Provide customers with the knowledge that if bumped, either one of the heated seat switches can be activated/deactivated accidentally. 2. Ensure customers have a thorough understanding of how the heated seat switches function. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Switch: > 05-08-49-018A > May > 06 > Instruments - Service Tire Monitor Message is Displayed Low Tire Pressure Indicator: All Technical Service Bulletins Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Page 1076 Seat Heater Switch: Locations Driver Door Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Page 1077 Front Passenger Door Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Page 1078 Seat Heater Switch: Diagrams Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Page 1079 Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Page 1080 Front Passenger Door Module (FPDM) - C5 (Heated Seat Switch) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Page 1081 Heated Seat Switch - Front Passenger (FPDM C5) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Page 1082 Memory/Heated Seat Switch - Driver (DDM C5) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Page 1083 Memory/Heated Seat Switch - Driver (DDM C5) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch Replacement - Front Seat Heater Switch: Service and Repair Heated Seat Switch Replacement - Front HEATED SEAT SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connector. 3. Release the retaining clips for the front seat heater switch assembly in order to remove the switch. 4. Remove the front seat heater switch assembly. INSTALLATION PROCEDURE 1. Install the front seat heater switch assembly to the front trim panel by pressing the switch into place until the switch is completely seated. 2. Connect the electrical connector to the front seat heater switch assembly. 3. Install the front trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch Replacement - Front > Page 1086 Seat Heater Switch: Service and Repair Heated Seat Switch Replacement - Rear HEATED SEAT SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the center console end panel. 2. Disconnect the electrical connector. 3. Remove the seat heater switch retaining screws. 4. Remove the switch from the vehicle. INSTALLATION PROCEDURE 1. Install the switch to the console panel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screw. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector. 4. Install the center console end panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations Driver Door Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 1090 Seat Memory Switch: Diagrams Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 1091 Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 1092 Memory/Heated Seat Switch - Driver (DDM C5) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 1093 Memory/Heated Seat Switch - Driver (DDM C5) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 1094 Seat Memory Switch: Service and Repair MEMORY SEAT SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connector. 3. Release the front seat memory switch assembly retaining clips in order to remove the switch. 4. Remove the front seat memory switch assembly. INSTALLATION PROCEDURE 1. Install the front seat memory switch assembly to the front trim panel by pressing into place until fully seated. 2. Connect the electrical connector to the front seat memory switch assembly. 3. Install the front trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Remove the MID-bussed electrical center from the bracket. 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch mounting bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Page 1099 1. Install the park brake warning lamp switch. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake warning lamp switch mounting bolt. ^ Tighten the bolt to 3 Nm (25 inch lbs.). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the MID-bussed electrical center to the bracket. 5. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations Traction Control Switch: Locations ABS Component Views Traction Control Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 1103 Traction Control Switch: Diagrams ABS Connector End Views Traction Control Switch (NW7) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 1104 Traction Control Switch: Service and Repair Traction Control Switch Replacement Removal Procedure 1. Remove instrument panel (IP) bezel. 2. Gently lift the switch retaining tabs (1) and remove the traction control switch (2) from the instrument panel (IP) assembly (3). 3. Disconnect the harness connector from the traction control switch. Installation Procedure 1. Connect the harness connector to the traction control switch. 2. Install the traction control switch (2) into the instrument panel (IP) assembly (3), making sure that all of the switch retaining tabs (1) are engaged. 3. Install instrument panel (IP) bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: Customer Interest Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set > Page 1113 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: All Technical Service Bulletins Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set > Page 1119 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 1120 Wheel Speed Sensor: Locations ABS Component Views Wheel Speed Sensor (WSS) - RF and LF Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 1121 Wheel Speed Sensor: Diagrams ABS Connector End Views Wheel Speed Sensor (WSS) - LF Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 1122 Wheel Speed Sensor (WSS) - RF Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 1123 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (4WD) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and wheel. 3. Remove the brake rotor (2) shown on the 1500 series. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the WSS cable mounting clip from the knuckle. 5. Remove the WSS cable mounting clip from the upper control arm. 6. Remove the WSS cable mounting clip from the frame attachment point. 7. Remove the WSS cable electrical connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 1124 8. Remove the wheel speed sensor (WSS) mounting bolt. 9. NOTICE: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. Remove the wheel speed sensor (5) from the hub/bearing assembly (4) shown on the 2500/3500 series. Installation Procedure 1. Plug the WSS bore to prevent debris from falling into the hub. 2. Using a wire brush or equivalent, clean the WSS mounting surface on the hub to remove any rust or corrosion. 3. Apply a thin layer of wheel bearing lubricant, GM P/N 01051344 to the hub surface and the sensor O-ring prior to sensor installation. 4. Install the WSS (5) into the hub/bearing assembly (4) shown on the 2500/3500 series. Ensure that the sensor is seated flat against the hub. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 1125 5. Notice: Refer to Fastener Notice in Service Precautions. Install the WSS mounting bolt. ^ Tighten the WSS mounting bolt to 18 Nm (13 ft. lbs.). 6. Install the WSS cable mounting clip to the knuckle. 7. Install the WSS cable mounting clip to the upper control arm. 8. Install the WSS cable mounting clip to the frame attachment point. 9. Connect the WSS cable electrical connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 1126 10. Install the brake rotor (2) shown on the 1500 series. Refer to Brake Rotor Replacement - Front in Disc Brakes. 11. Install the tire and wheel. 12. Perform the Diagnostic System Check - ABS. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Locations Left Side Of The Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Locations > Page 1131 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Upper Front of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1136 Engine Coolant Temperature (ECT) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1137 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the coolant to a level below the engine coolant temperature (ECT) sensor. 2. Disconnect the ECT sensor electrical connector. 3. Remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1138 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor (1). Tighten Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector. 4. Fill the cooling system, if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Service and Repair Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Remove the lower oil pan. 2. Remove the oil level sensor clip (3). 3. Remove the oil level sensor bolt (2) and sensor (1). Installation Procedure Important: When routing the oil level sensor wire, ensure that the wire is routed along the side of the oil pan. 1. Install the oil level sensor (1) and bolt (2). Tighten the bolt to 9 Nm (80 inch lbs.). 2. Install the oil level sensor clip (3). 3. Install the lower oil pan. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor For ECM > Component Information > Locations Oil Level Sensor For ECM: Locations Left Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor For ECM > Component Information > Locations > Page 1150 Left Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor For ECM > Component Information > Locations > Page 1151 Engine Oil Level Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Left Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1155 Left Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1156 Oil Pressure Sender: Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the left wheelhouse inner panel. Important: Clean the area around the sensor. Do not allow debris to enter the engine. 2. Disconnect the oil pressure sensor electrical connector. 3. Using J 41712, remove the oil pressure sensor (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair > Page 1160 Installation Procedure 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 41712, install the oil pressure sensor (1). Tighten the sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector. 4. Install the left wheelhouse inner panel. 5. Check and add engine oil if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Air Temperature Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 1165 Ambient Air Temperature Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 1166 Ambient Temperature Sensor / Switch HVAC: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2-wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: Ambient Air Temperature Sensor - Inside Air Temperature Sensor Assembly - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Air Temperature Sensor A signal and a low-reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0.5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated under the above conditions. The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 1167 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the Park/Turn Signal. 2. Disconnect the electrical connector from the ambient air temperature sensor (3). 3. Remove the ambient air temperature sensor (3). INSTALLATION PROCEDURE 1. Install the ambient air temperature sensor (3). 2. Connect the electrical connector to the ambient air temperature sensor (3). 3. Install the Park/Turn Signal. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Diagrams Inside Air Temperature Sensor Assembly Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Diagrams > Page 1171 Cabin Temperature Sensor / Switch: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2-wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: Ambient Air Temperature Sensor - Inside Air Temperature Sensor Assembly - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Air Temperature Sensor A signal and a low-reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0.5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated under the above conditions. The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Diagrams > Page 1172 Cabin Temperature Sensor / Switch: Service and Repair INSIDE AIR TEMPERATURE SENSOR ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the left windshield garnish molding. 2. Remove the left center pillar assist handle. 3. Remove the left center pillar garnish molding. 4. Remove the left sunshade. 5. Gently pull down the headliner. 6. Disconnect the electrical connector from the inside air temperature sensor. 7. Partially remove the inside air temperature sensor from the headliner. 8. Remove the sensor grille from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. INSTALLATION PROCEDURE 1. Install the new sensor grille to the headliner. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Diagrams > Page 1173 2. Install the inside air temperature sensor to the headliner and sensor grille. 3. Connect the electrical connector to the inside air temperature sensor. 4. Install the left sunshade. 5. Install the left center pillar garnish molding. 6. Install the left center assist handle. 7. Install the left windshield garnish molding. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations Discharge Air Temperature Sensor / Switch: Locations Air Temperature Sensors - Upper Left And Right Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations > Page 1177 Air Temperature Sensors - Lower Left Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations > Page 1178 Air Temperature Sensors - Lower Right Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper Left Air Temperature Sensor - Upper Left Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper Left > Page 1181 Air Temperature Sensor - Upper Right Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper Left > Page 1182 Air Temperature Sensor - Lower Left Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper Left > Page 1183 Air Temperature Sensor - Lower Right Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Diagrams > Page 1184 Discharge Air Temperature Sensor / Switch: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2-wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: Ambient Air Temperature Sensor - Inside Air Temperature Sensor Assembly - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Air Temperature Sensor A signal and a low-reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0.5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated under the above conditions. The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper Right Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Upper Right AIR TEMPERATURE SENSOR REPLACEMENT - UPPER RIGHT REMOVAL PROCEDURE 1. Remove the I/P upper trim panel. 2. Disconnect the electrical connector (1) from the upper right air temperature sensor (2). 3. Remove the upper right air temperature sensor (1) from the air distributor duct (3). INSTALLATION PROCEDURE 1. Install the upper right air temperature sensor (1) to the air distributor duct (3). 2. Connect the electrical connector (1) from the upper right air temperature sensor (2). 3. Install the I/P upper trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper Right > Page 1187 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Upper Left AIR TEMPERATURE SENSOR REPLACEMENT - UPPER LEFT REMOVAL PROCEDURE 1. Remove the upper left air temperature sensor (2) from the air distributor duct (1). 2. Disconnect the electrical connector (3) from the upper left air temperature sensor (2). INSTALLATION PROCEDURE 1. Install the upper left air temperature sensor (2) to the air distributor duct (1). 2. Connect the electrical connector (3) to the upper left air temperature sensor (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper Right > Page 1188 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower Left AIR TEMPERATURE SENSOR REPLACEMENT - LOWER LEFT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the lower left air temperature sensor (1). 2. Remove the lower left air temperature sensor (1) from the HVAC module (2). INSTALLATION PROCEDURE 1. Install the lower left air temperature sensor (1) to the HVAC module (2). 2. Connect the electrical connector to the lower left air temperature sensor (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper Right > Page 1189 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower Right AIR TEMPERATURE SENSOR REPLACEMENT - LOWER RIGHT REMOVAL PROCEDURE 1. Remove the I/P lower closeout panel. 2. Remove the right floor duct. 3. Remove the center console. 4. Disconnect the electrical connector from the lower right air temperature sensor (1). 5. Remove the lower right air temperature sensor (1). INSTALLATION PROCEDURE 1. Install the lower right air temperature sensor (1). 2. Connect the electrical connector to the lower right air temperature sensor (1). 3. Install the center console. 4. Install the right floor duct. 5. Install the I/P lower closeout panel Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Air Conditioning - Diagnose A/C Low Pressure Switch Low Pressure Sensor / Switch: Technical Service Bulletins Air Conditioning - Diagnose A/C Low Pressure Switch INFORMATION Bulletin No.: 04-01-38-010A Date: January 21, 2010 Subject: Diagnostic Information to Accurately Diagnose A/C Low Pressure Switch Using Kent Moore Special Tool GE-47742 Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2007 Chevrolet Silverado 2000-2006 Chevrolet Suburban, Tahoe 2002-2007 Chevrolet Avalanche 1999-2007 GMC Sierra 2000-2006 GMC Yukon, Yukon XL 2001-2006 GMC Yukon Denali XL 2001-2007 GMC Sierra Denali, Yukon Denali XL 2003-2008 HUMMER H2 with Air Conditioning Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 04-01-38-010 (Section 01 - HVAC). Currently, technicians cannot accurately determine the air conditioning (A/C) low pressure switch open/close pressure point by measuring pressure at the low side service port. This is because the evaporator is between the low side service port and the A/C low pressure switch. Correlating pressures measured at the low side service port to actual pressures at the A/C low pressure switch port is difficult because of the multiple variables that impact pressure drop across the evaporator. Providing a pressure range that would take into account all these variables would result in a pressure range that would be too broad to be useful for diagnostic purposes. Kent Moore special tool GE-47742 will allow technicians to monitor the actual pressures at which the A/C low pressure switch opens and closes under actual operating conditions. Technicians are to use the following steps to install and use Kent Moore special tool GE-47742 to measure A/C low pressure switch opening and closing pressures: 1. Disconnect the wire harness from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Install the A/C low pressure switch, using the threaded port with an O-ring, onto special tool GE-47742. 4. Install special tool GE-47742, with the A/C low pressure switch attached, onto the accumulator. Important Removing the seal from the A/C low pressure switch wire harness connector is required. Failure to remove the seal before plugging it into the switch will lead to misdiagnosis. The "plunger effect" of plugging the connector with a seal into the A/C low pressure switch induces a pressure on the back side of the switch. This pressure will skew the opening/closing characteristics of the switch 34-69 kPa (5-10 psi) until the pressure bleeds off. The time required for the connection induced pressure to bleed off can be 20 minutes or longer. 5. Remove the seal from the A/C low pressure switch wire harness connector. 6. Connect the wire harness, without the seal, to the A/C low pressure switch. 7. Connect the low side service hose from the ACR2000(R) or GE-48800 to the service port on special tool GE-47742. 8. Connect a Tech2(R) to the vehicle. 9. Start the vehicle and maintain an engine speed of 1500 RPM. Set the HVAC controls as follows: - Set the A/C control switch to ON. - Set the mode control switch to A/C and engage recirculation mode. - Set the blower motor speed to LOW. - Set the temperature control to full cold. - Set the auxiliary blower motor speed to LOW. If equipped. - Set the auxiliary temperature control to full cold. If equipped. - The vehicle must be operating with no sun load (in the shade). 10. Use the Tech2(R) to determine the A/C low pressure switch status and the ACR2000(R) or GE-48800 to determine the A/C low side pressure. Simultaneously monitor the switch status and the pressure at which the A/C low pressure switch opens and closes. The Tech2(R) will display switch status as "Normal" for Closed and "Low Pressure" for Open. A properly operating switch should open between 138-172 kPa (20-25 psi) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Air Conditioning - Diagnose A/C Low Pressure Switch > Page 1198 and close between 275-317 kPa (40-46 psi). 11. Remove special tool GE-47742 after diagnosis is complete. 12. Install a new O-ring on the A/C low pressure switch port on the accumulator. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. 13. Install the A/C low pressure switch onto the accumulator. Tighten Tighten the A/C low pressure switch to 6 Nm (44 lb in). Important Remember to install the seal back onto the A/C low pressure switch wire harness connector. Failure to replace the seal could result in terminal corrosion. 14. Reconnect the wire harness to the A/C low pressure switch. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 1199 Low Pressure Sensor / Switch: Locations Right Side Of The Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 1200 A/C Low Pressure Switch And A/C Accumulator Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 1201 Right Side Of Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Diagrams > HVAC System - Manual A/C Low Pressure Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Diagrams > HVAC System - Manual > Page 1204 A/C Low Pressure Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 1205 Low Pressure Sensor / Switch: Description and Operation A/C LOW PRESSURE SWITCH The A/C low pressure switch protects the A/C system from a low pressure condition that could damage the A/C compressor or cause evaporator icing. The HVAC control module applies 5 volts to the A/C low pressure switch signal circuit. The switch will open when the A/C low side pressure reaches 165-200 kPa (24-29 psi). This prevents the A/C compressor from operating. The switch will then close when A/C low pressure side reaches 275-310 kPa (40-45 psi). This enables the A/C compressor to turn back ON. The low pressure switch uses refrigerant pressure to open and close a set of electrical contacts. When A/C request is authorized, the switch is closed and shows normal status. During this state, the switch will show 0 volts on the A/C low pressure sensor signal circuit. When A/C request is denied due to a low pressure condition, the switch will be open. During this state, the switch will show 5 volts on the A/C low pressure sensor signal circuit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 1206 Low Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Remove the O-ring and discard. INSTALLATION PROCEDURE 1. Lightly coat the NEW O-ring seal with mineral base 525 viscosity refrigerant oil. 2. Install the NEW O-ring seal to the switch. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the A/C low pressure switch to the accumulator. Tighten Tighten the switch to 6 N.m (53 lb in). 4. Connect the electrical connector to the A/C low pressure switch. 5. Leak test the fittings of the components using the J 39400-A. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations Ambient Light Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 1210 Solar Sensor: Diagrams Sunload Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 1211 Sunload Sensor (With RPO Code CJ2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 1212 Solar Sensor: Service and Repair SUN LOAD SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel (I/P) upper trim panel. 2. Remove the sun load sensor (2) from the upper trim panel. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the sun load sensor (2) to the upper trim panel. 3. Install the I/P upper trim panel- Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Driver C2 Door Latch Assembly (Door Jamb Switch) - Driver C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 1218 Door Latch Assembly (Door Jamb Switch) - Driver - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 1219 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Front Passenger C2 Door Latch Assembly (Door Jamb Switch) - Front Passenger C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 1220 Door Latch Assembly (Door Jamb Switch) - Front Passenger - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 1221 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - LR C2 (Crew Cab Only) Door Latch Assembly (Door Jamb Switch) - LR C2 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 1222 Door Latch Assembly (Door Jamb Switch) - LR - C2 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 1223 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - RR C2 (Crew Cab Only) Door Latch Assembly (Door Jamb Switch) - RR C2 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 1224 Door Latch Assembly (Door Jamb Switch) - RR - C2 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 1225 Door Switch: Description and Operation DOOR LATCH (DOOR JAMB) SWITCHES The theft deterrent system uses the door key switch as one method in order to activate the alarm. If the BCM detects any door opening before the BCM receives a disarm input, the alarm mode activates. DOOR KEY SWITCH The BCM monitors the door key switches in order to disarm the CTD system. When the lock cylinder turns in order to unlock the door, the switch grounds the disarm input to the BCM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications Fuel Gauge Sender: Specifications FUEL LEVEL SPECIFICATIONS Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 1229 The values in the table are approximate values based on information obtained from properly operating vehicles. Actual results may vary slightly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 1230 Fuel Gauge Sender: Locations Fuel Tank - Primary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 1231 Fuel Tank - Secondary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 1232 Fuel Gauge Sender: Diagrams Fuel Level Sensor - Primary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 1233 Fuel Level Sensor - Secondary W/Dual Tanks Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 1234 Fuel Level Sensor - Primary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 1235 Fuel Level Sensor - Secondary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 1236 Fuel Gauge Sender: Description and Operation FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The engine control module (ECM) sends the fuel level information via the class 2 circuit to the instrument panel cluster (IPC). This information is used for the instrument panel (I/P) fuel gage and the low fuel warning indicator, if applicable. The ECM also monitors the fuel level input for various diagnostics. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 1237 Fuel Gauge Sender: Service and Repair FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel level sensor electrical connector (1). 3. Remove the sensor retaining clip (3). 4. Squeeze the locking tangs (2) and remove the fuel level sensor. INSTALLATION PROCEDURE 1. Install the fuel level sensor. 2. Install the sensor retaining clip (3). 3. Connect the sensor electrical connector (1). 4. Install the sending unit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Locations Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations Air Temperature Sensor - Outside Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations > Page 1244 Ambient Air Temperature Sensor - Outside Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations > Page 1245 Outside Temperature Display Sensor: Service and Repair AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the radiator grille from the vehicle. 2. Remove the push pin retainer from the sensor mounted on the radiator support brace. 3. Disconnect the electrical connector from the sensor. INSTALLATION PROCEDURE 1. Connect the electrical connector to the sensor. 2. Install the sensor to the radiator support brace and install the push pin retainer. 3. Install the radiator grille to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Remove the MID-bussed electrical center from the bracket. 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch mounting bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Page 1249 1. Install the park brake warning lamp switch. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake warning lamp switch mounting bolt. ^ Tighten the bolt to 3 Nm (25 inch lbs.). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the MID-bussed electrical center to the bracket. 5. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations Water In Fuel Sensor: Locations Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 1253 Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 1254 Water In Fuel (WIF) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Service and Repair > Water-In-Fuel Sensor Replacement Water In Fuel Sensor: Service and Repair Water-In-Fuel Sensor Replacement WATER-IN-FUEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Drain the fuel from the fuel filter. Refer to Water-in-Fuel Draining Procedure. 2. Remove the right front wheelhouse panel. 3. Disconnect the fuel filter electrical connectors. 4. Remove the water-in-fuel sensor (3) from the fuel filter (2). INSTALLATION PROCEDURE IMPORTANT: The water-in-fuel sensor must ONLY be tightened by hand. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Service and Repair > Water-In-Fuel Sensor Replacement > Page 1257 1. Install the water-in-fuel sensor (3) to the fuel filter (2). 2. Connect the fuel filter electrical connector. 3. Install the right front wheelhouse panel. 4. Prime the fuel system. Refer to Fuel System Priming. 5. Start the engine. If the engine stalls, repeat the above step. 6. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Service and Repair > Water-In-Fuel Sensor Replacement > Page 1258 Water In Fuel Sensor: Service and Repair Water-In-Fuel Draining Procedure WATER-IN-FUEL DRAINING PROCEDURE 1. Attach a small piece of hose to the drain cock onto the water-in-fuel sensor. 2. Place an approved fuel-resistant container under the fuel filter. 3. Open the drain cock 3 or 4 turns or until the water contaminated fuel seeps from the drain cock. 4. Operate the priming pump until only diesel fuel is visible. Allow the pump to return upward between pushes. 5. Tighten the drain cock. 6. Remove the container and hose. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ambient Light Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 1263 Ambient Light Sensor: Diagrams Ambient Light Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 1264 Ambient Light Sensor (With RPO Code CJ3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 1265 Ambient Light Sensor: Service and Repair AMBIENT LIGHT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel top cover. 2. Disconnect the electrical connector (1) to the ambient light sensor on the underside of the IP top cover. 3. Turn the ambient light sensor 1/4 turn and remove it from the IP top cover. INSTALLATION PROCEDURE 1. Install the ambient light sensor to the underside of the IP top cover, turning it 1/4 turn to secure it in place. 2. Connect the electrical connector (1) to the ambient light sensor on the underside of the IP top cover. 3. Install the instrument panel top cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams Backup Lamp - Switch (Manual Trans) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > NV 3500 Backup Lamp Switch: Service and Repair NV 3500 Backup Lamp Switch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the backup lamp switch electrical connector (3). 3. Remove the backup lamp switch. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Important: The backup lamp switch has pre-applied thread sealant on the threads. Install the backup lamp switch. ^ Tighten the switch to 37 Nm (27 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > NV 3500 > Page 1271 2. Connect the backup lamp switch electrical connector (3). 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > NV 3500 > Page 1272 Backup Lamp Switch: Service and Repair NV 4500 Backup Lamp Switch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the backup lamp switch electrical connector (1). 3. Remove the backup lamp switch and seal. Installation Procedure 1. Ensure the seal is installed on the switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the backup lamp switch. ^ Tighten the switch to 28 Nm (21 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > NV 3500 > Page 1273 3. Connect the backup lamp switch electrical connector (1). 4. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > NV 3500 > Page 1274 Backup Lamp Switch: Service and Repair ZF S6-650 Backup Lamp Switch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. If equipped with a 6.6L engine, disconnect the backup lamp switch electrical connector (3). 2. If equipped with a 8.1L engine, disconnect the backup lamp switch electrical connector (4). 3. Remove the backup lamp switch. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > NV 3500 > Page 1275 1. Notice: Refer to Fastener Notice in Service Precautions. Install the backup lamp switch. ^ Tighten the switch to 20 Nm (15 ft. lbs.). 2. If equipped with a 8.1L engine, connect the backup lamp switch electrical connector (4). 3. If equipped with a 6.6L engine, connect the backup lamp switch electrical connector (3). Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations ABS Component Views Stoplamp Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 1279 Brake Light Switch: Diagrams Stop Lamp Switch Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 1280 Stop Lamp Switch Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 1281 Brake Light Switch: Service and Repair STOP LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the stop lamp switch (2). 2. Remove the pushrod retaining clip (4). 3. Remove the stop lamp switch (2). INSTALLATION PROCEDURE 1. Install the stop lamp switch (2). 2. Install the pushrod retaining clip (4). 3. Connect the electrical connector to the stop lamp switch (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Locations Instrument Panel Switches-LH Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Locations > Page 1285 Cargo Lamp Switch: Service and Repair LAMP SWITCH ASSEMBLY REPLACEMENT - FRONT FOG LAMP AND CARGO LAMP REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Remove the fog lamp switch and cargo switch from the housing. 3. Disconnect the electrical connector(s) from the fog lamp switch. 4. Remove the fog lamp and cargo lamp switch from the housing. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the fog lamp and cargo lamp switch. 2. Install the fog lamp switch into the housing. 3. Install the IP trim bezel to the instrument panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Combination Switch: Locations Steering Wheel and Column Sub-System Components Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 1289 Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 1290 Steering Wheel And Column Sub-System Components Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 1291 Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 1292 Combination Switch: Diagrams Multifunction Accessory Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 1293 Turn Signal Multifunction Switch - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 1294 Turn Signal Multifunction Switch - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 1295 Turn Signal Multifunction Switch - C3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 1296 Turn Signal Multifunction Switch - C4 (With RPO Code K34) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Driver C2 Door Latch Assembly (Door Jamb Switch) - Driver C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 1301 Door Latch Assembly (Door Jamb Switch) - Driver - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 1302 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Front Passenger C2 Door Latch Assembly (Door Jamb Switch) - Front Passenger C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 1303 Door Latch Assembly (Door Jamb Switch) - Front Passenger - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 1304 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - LR C2 (Crew Cab Only) Door Latch Assembly (Door Jamb Switch) - LR C2 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 1305 Door Latch Assembly (Door Jamb Switch) - LR - C2 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 1306 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - RR C2 (Crew Cab Only) Door Latch Assembly (Door Jamb Switch) - RR C2 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 1307 Door Latch Assembly (Door Jamb Switch) - RR - C2 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 1308 Door Switch: Description and Operation DOOR LATCH (DOOR JAMB) SWITCHES The theft deterrent system uses the door key switch as one method in order to activate the alarm. If the BCM detects any door opening before the BCM receives a disarm input, the alarm mode activates. DOOR KEY SWITCH The BCM monitors the door key switches in order to disarm the CTD system. When the lock cylinder turns in order to unlock the door, the switch grounds the disarm input to the BCM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations Fog/Driving Lamp Switch: Locations Instrument Panel Switches-LH Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 1312 Accessory Switch Housing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 1313 Fog Lamp Switch Rear (With RPO Code T79) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Lamp Switch Assembly Replacement-Front Fog Lamp and Cargo Lamp Fog/Driving Lamp Switch: Service and Repair Lamp Switch Assembly Replacement-Front Fog Lamp and Cargo Lamp LAMP SWITCH ASSEMBLY REPLACEMENT - FRONT FOG LAMP AND CARGO LAMP REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Remove the fog lamp switch and cargo switch from the housing. 3. Disconnect the electrical connector(s) from the fog lamp switch. 4. Remove the fog lamp and cargo lamp switch from the housing. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the fog lamp and cargo lamp switch. 2. Install the fog lamp switch into the housing. 3. Install the IP trim bezel to the instrument panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Lamp Switch Assembly Replacement-Front Fog Lamp and Cargo Lamp > Page 1316 Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement - Rear FOG LAMP SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the instrument panel bezel. 2. Pull out the accessary switch housing. 3. Disconnect the electrical connectors. 4. Remove the fog lamp switch from the accessary switch housing. INSTALLATION PROCEDURE 1. Install the fog lamp switch into accessary switch housing. 2. Connect the electrical connectors. 3. Install the accessary switch housing. 4. Install the instrument panel bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair INSTRUMENT PANEL (I/P) COMPARTMENT LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Lower the instrument panel storage compartment door by pressing in the tab. 2. With one hand holding the plunger of the switch, use a small screw driver to push in the tabs on each side while pulling outwards. 3. Pull the switch assembly from the I/P. 4. Disconnect the electrical connector. 5. Remove the bulb (1). INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair > Page 1320 1. Install the bulb (1) into the socket. 2. Connect the electrical connector. 3. Install the switch until the tabs (1) click in place. 4. Close the compartment door. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Hazard Warning Switch: Locations Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 1324 Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Alignment Switch > Component Information > Diagrams Headlamp Leveling Switch (Export) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Alignment Switch > Component Information > Diagrams > Page 1328 Headlamp Alignment Switch: Service and Repair HEADLAMP LEVELING SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel bezel. 2. Pull out the accessary switch housing. 3. Disconnect the electrical connectors. 4. Remove the head lamp leveling switch from the accessary switch housing. INSTALLATION PROCEDURE 1. Install the head lamp leveling switch into accessary switch housing. 2. Connect the electrical connectors. 3. Install the accessary switch housing. 4. Install the instrument panel bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Instrument Panel Switches-LH Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams Headlamp Switch: Diagrams Headlamp Switch Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 1335 Headlamp Switch Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 1336 Headlamp Switch: Service and Repair HEADLAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Unsnap the switch from the housing. 3. Disconnect the electrical connectors. 4. Remove the switch. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 1337 1. Connect the electrical connectors. 2. Install the headlamp switch by snapping the headlamps switch into place. 3. Install the bezel to the instrument panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Horn Switch: Locations Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 1341 Steering Wheel And Column Sub-System Components Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 1342 Steering Wheel and Column Sub-System Components Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 1343 Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 1344 Horn Switch: Service and Repair Horn Switch Replacement Removal Procedure 1. Caution: Refer to Servicing the SIR System Caution in Cautions and Notices. Disable the SIR system. 2. Remove the inflatable restraint steering wheel module. 3. Remove the horn plunger from the steering column by pressing inward to the stop and rotating the horn plunger 90 degrees. 4. Disconnect the captured screws (1,4) to the horn contact plate (2) from the steering wheel (3). 5. Remove the horn switch (2) from the steering wheel (3). Installation Procedure 1. Install the horn switch (2) to the steering wheel (3). 2. Notice: Refer to Fastener Notice in Service Precautions. Connect the captured screws (1,4) from the horn contact plate (2) to the steering wheel (3). ^ Tighten the screws to 5.5 Nm (50 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 1345 3. Install the horn plunger to the steering column. 4. Install the inflator module. 5. Enable the SIR system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 1349 Steering Wheel And Column Sub-System Components Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 1350 Steering Wheel and Column Sub-System Components Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 1351 Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 1352 Turn Signal Switch: Diagrams Turn Signal Multifunction Switch - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 1353 Turn Signal Multifunction Switch - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 1354 Turn Signal Multifunction Switch - C3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 1355 Turn Signal Multifunction Switch - C4 (With RPO Code K34) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1361 Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1362 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SYSTEM DESCRIPTION The accelerator pedal position (APP) system along with the vehicle electronics and components is used to calculate and control the amount of acceleration and deceleration via fuel injector control. This eliminates the need for a mechanical cable attachment from the accelerator pedal to a throttle body. The APP system includes, but is not limited to, the following components : - The accelerator pedal position (APP) sensor assembly - The engine control module (ECM) Accelerator Pedal Position (APP) Sensor The accelerator pedal position (APP) sensor is mounted on the accelerator pedal control assembly. The sensor is made up of 3 individual sensors within one housing. Three separate signal, low reference, and 5-volt reference circuits are used in order to interface the accelerator pedal sensor assembly with the ECM. Each sensor has a unique functionality to determine pedal position. The ECM uses the APP sensor to determine the amount of acceleration or deceleration desired by the person driving the vehicle. The APP sensor 1 voltage should increase as the accelerator pedal is depressed, from below 1.0 volt at 0 pedal travel to above 2 volts at 100 percent pedal travel. APP sensor 2 voltage should decrease from above 4 volts at 0 pedal travel to below 3.0 volts at 100 percent pedal travel. APP sensor 3 voltage should decrease from above 3.8 volts at 0 percent pedal travel to below 3.3 volts at 100 percent pedal travel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1363 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION (APP) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector. 3. Reposition the carpet to access the lower nut. 4. Remove the accelerator pedal nuts. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1364 1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Service Precautions. 2. Install the accelerator pedal nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Connect the APP sensor electrical connector. 4. Reposition the carpet. 5. Install the CPA retainer. 6. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 7. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle and a wide open throttle (WOT). 8. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 9. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Mass Air Flow (MAF) Sensor: Locations Right Side Of The Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1368 Right Side Of Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1369 Intake Air Temperature (IAT)/Mass Airflow (MAF) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1370 Mass Air Flow (MAF) Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector (1). 2. Remove the MAF/IAT sensor TORX(R) screws. 3. Remove the MAF/IAT sensor (1). INSTALLATION PROCEDURE 1. Install the MAF/IAT sensor (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1371 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the MAF/IAT sensor TORX(R) screws. Tighten Tighten the screws to 8 N.m (70 lb in). 3. Connect the MAF/IAT sensor electrical connector (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations Barometric Pressure Sensor: Locations Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 1375 Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 1376 BARO Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 1377 Barometric Pressure Sensor: Service and Repair BAROMETRIC PRESSURE (BARO) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the barometric pressure (BARO) sensor electrical connector. 2. Push the BARO sensor (1) downward in order to remove it from the bracket. INSTALLATION PROCEDURE 1. Push the BARO sensor (1) upward in order to remove it from the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 1378 2. Connect the BARO sensor electrical connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Brake Pressure Switch > Component Information > Locations Chassis And License Lamp Harnesses Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Right Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1385 Camshaft Position (CMP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Replacement CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the cooling fan pulley. 2. Remove the camshaft position (CMP) sensor bolt. 3. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Lubricate the CMP sensor O-ring with clean engine oil. 2. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the CMP sensor bolt. Tighten Tighten the bolt to 10 N.m (89 lb in). 4. Install the cooling fan pulley. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement > Page 1388 Camshaft Position Sensor: Service and Repair Camshaft Reluctor Replacement Camshaft Reluctor Replacement Removal Procedure Notice: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 1. Remove the engine front cover. 2. While holding the secondary oil pump shaft with a hex driver, remove the oil pump driven gear nut. 3. Remove the oil pump driven gear. 4. Important: DO NOT remove the reluctor from the oil pump drive gear. The reluctor is timed to the gear and once removed the correct timing will be lost. Remove the oil pump drive gear and crankshaft sensor reluctor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement > Page 1389 5. Remove the camshaft reluctor screws. 6. Remove the camshaft reluctor. 7. Clean and Inspect the camshaft reluctor for damage. Replace the reluctor if damage is found. Installation Procedure 1. Position the camshaft reluctor to the camshaft gear. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the camshaft reluctor bolts. Tighten the bolts to 9 Nm (80 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement > Page 1390 3. Important: Do not damage the teeth on the reluctor. Install the oil pump drive gear and reluctor to the crankshaft. 4. Install the oil pump driven gear. 5. While holding the secondary oil pump shaft with a hex driver, install the oil pump driven gear nut. Tighten the nut to 100 Nm (74 ft. lbs.). 6. Install the engine front cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations SEO Harness Routing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Upper Front of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1397 Engine Coolant Temperature (ECT) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1398 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the coolant to a level below the engine coolant temperature (ECT) sensor. 2. Disconnect the ECT sensor electrical connector. 3. Remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1399 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor (1). Tighten Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector. 4. Fill the cooling system, if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Starter Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1403 Right Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1404 Crankshaft Position (CKP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1405 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the right wheelhouse panel. 3. Disconnect the crankshaft position (CKP) sensor electrical connector. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. 6. If necessary, remove the CKP sensor spacer bolts. 7. If necessary, remove the CKP sensor spacer. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1406 1. If necessary, lubricate a NEW CKP spacer O-ring with clean engine oil. 2. If necessary, install the NEW O-ring to the CKP sensor spacer. IMPORTANT: The crankshaft position sensor spacers are machined with different timing positions. However, if the crankshaft position sensor spacer requires replacement, replace with a grade "C" spacer. 3. If necessary, install the CKP sensor spacer. NOTE: Refer to Fastener Notice in Service Precautions. 4. If necessary, install the CKP sensor spacer bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). 5. Lubricate a NEW CKP sensor O-ring with clean engine oil. 6. Install the NEW O-ring to the CKP sensor. 7. Install the CKP sensor. 8. Install the CKP sensor bolt. Tighten Tighten the bolt to 10 N.m (89 lb in). 9. Connect the CKP sensor electrical connector. 10. Install the right wheelhouse panel. 11. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Fuel Tank - Primary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1410 Fuel Tank - Secondary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1411 Fuel Level Sensor: Diagrams Fuel Level Sensor - Primary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1412 Fuel Level Sensor - Secondary W/Dual Tanks Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1413 Fuel Level Sensor - Primary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1414 Fuel Level Sensor - Secondary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1415 Fuel Level Sensor: Description and Operation FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The engine control module (ECM) sends the fuel level information via the class 2 circuit to the instrument panel cluster (IPC). This information is used for the instrument panel (I/P) fuel gage and the low fuel warning indicator, if applicable. The ECM also monitors the fuel level input for various diagnostics. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1416 Fuel Level Sensor: Service and Repair FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel level sensor electrical connector (1). 3. Remove the sensor retaining clip (3). 4. Squeeze the locking tangs (2) and remove the fuel level sensor. INSTALLATION PROCEDURE 1. Install the fuel level sensor. 2. Install the sensor retaining clip (3). 3. Connect the sensor electrical connector (1). 4. Install the sending unit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Pressure Sensor > Component Information > Locations Fuel Pressure Sensor: Locations Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Pressure Sensor > Component Information > Locations > Page 1420 Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Pressure Sensor > Component Information > Locations > Page 1421 Fuel Pressure Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Pressure Sensor > Component Information > Locations > Page 1422 Fuel Pressure Sensor: Service and Repair FUEL RAIL PRESSURE (FRP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet duct. 2. Remove the exhaust gas recirculation (EGR) cooler tube. 3. Disconnect the fuel rail pressure sensor electrical connector. 4. Prior to removal, clean the fuel pressure sensor and surrounding area thoroughly with solvent, such as GM P/N 12377981 (Canadian P/N 10953463) or equivalent. 5. Using compressed air, thoroughly blow dry the sensor and surrounding area. 6. Remove the fuel pressure sensor (1). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Pressure Sensor > Component Information > Locations > Page 1423 1. Install the fuel pressure sensor (1). Tighten Tighten the sensor to 70 N.m (52 lb ft). 2. Connect the fuel rail pressure sensor electrical connector. 3. Install the EGR cooler tube. 4. Install the air cleaner outlet duct. 5. Prime the fuel system. Refer to Fuel System Priming. 6. Start the engine. If the engine stalls, repeat the above step. 7. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Intake Air Temperature (IAT) Sensor: Locations Intake Air Temperature (IAT) Sensor is part of the Mass Air Flow (MAF) Sensor and is in the air induction tube. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 1427 Intake Air Temperature (IAT)/Mass Airflow (MAF) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 1428 Intake Air Temperature (IAT) Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector (1). 2. Remove the MAF/IAT sensor TORX(R) screws. 3. Remove the MAF/IAT sensor (1). INSTALLATION PROCEDURE 1. Install the MAF/IAT sensor (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 1429 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the MAF/IAT sensor TORX(R) screws. Tighten Tighten the screws to 8 N.m (70 lb in). 3. Connect the MAF/IAT sensor electrical connector (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations Oil Level Sensor For ECM: Locations Left Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations > Page 1433 Left Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations > Page 1434 Engine Oil Level Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the left wheelhouse inner panel. Important: Clean the area around the sensor. Do not allow debris to enter the engine. 2. Disconnect the oil pressure sensor electrical connector. 3. Using J 41712, remove the oil pressure sensor (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 1438 Installation Procedure 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 41712, install the oil pressure sensor (1). Tighten the sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector. 4. Install the left wheelhouse inner panel. 5. Check and add engine oil if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start Transmission Position Switch/Sensor: Customer Interest A/T - Slow/No Gear Engagement/Engine No Start Bulletin No.: 02-07-30-011C Date: June 21, 2004 TECHNICAL Subject: Slow or No Engagement of Automatic Transmission, No Start, Blank PRNDL Display, Flashing PRNDL, DTC P0708, P0872, P0847, P0875, P1711, P1713 or U1000 Set (Diagnose Condition, Repair According to Procedure) Models: 2001-2004 Chevrolet Silverado 2001-2004 GMC Sierra with Allison(R) LCT1000 Automatic Transmission (RPO M74) and 6.6L Duramax(TM) Diesel Engine (RPO LB7) or 8.1L Gas Engine (RPO L18) Supercede: This bulletin is being revised to add model years and additional model information and add graphics. Please discard Corporate Bulletin Number 02-07-30-011B (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions. ^ The PRNDL display is flashing. ^ The engine will not start. ^ The "Service Engine Soon" Indicator lamp is illuminated. ^ The transmission does not shift properly. ^ The vehicle will not move, transmission will not engage. Cause Moisture contamination within the Park Neutral Position (PNP) Switch may cause this condition. This is sometimes referred to as the Neutral Start Back-up (NSBU) Switch. On a left turn, water spray from the left front tire is directed directly at this switch. Proper installation of the "Front Shield" and "Rear Shield" are essential for proper repairs. Technician Diagnosis This bulletin ONLY applies to vehicles equipped with a two connector PNP switch as shown above. A complete and through diagnosis must be performed by a qualified electrical technician to determine the cause and avoid needless replacement of good components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 1447 Important: The Transmission Control Module (TCM) and or the Pressure Switch Manifold (PSM) should NOT be replaced unless properly diagnosed. They are probably not the cause of the concern. It is often assumed the module is the cause of the concern when, in fact, it is another component or the wiring between the components that causes the concern. Important: Remember, everything starts with a properly operating Neutral Start Back Up (NSBU) switch. The NSBU switch has been incorporated into what is now called the Park Neutral Position (PNP) switch. If the PNP switch does not provide the proper voltage signal to the module indicating the transmission is in either Park or Neutral, the module will not allow the starter operation. After the engine is started, and the shift lever is moved to either Reverse or one of the drive positions, the range selected portion of the PNP switch portion provides a voltage input to the module as to what range the driver has manually selected for transmission operation. The module then controls pressures, shift points and other transmission functions based on the voltage input received from the range portion of the PNP switch. The technician may find one or more of the following conditions. The list of these conditions does not imply any type of frequency or order. They are random events and may occur in any order. ^ DTC P0708, Neutral start/backup (PNP or NSBU) switch ^ DTC P0847, Pressure Switch Manifold (PSM) ^ DTC P0872, Pressure Switch Manifold (PSM) ^ DTC P0875, Pressure Switch Manifold (PSM) ^ DTC P1711, Pressure Switch Manifold (PSM) ^ DTC P1713, Pressure Switch Manifold (PSM) ^ DTC U1000, Serial Data Communications ^ Blank PRNDL Display ^ Flashing PRNDL Display ^ Slow or No Engagement of Automatic Transmission Blank PRNDL Display A blank PRNDL display may indicate a condition with the PNP switch and/or one or more of the four signal circuits from the PNP to the TCM. 1. Pin A, Circuit 771 (BLK/WHT) 2. Pin B, Circuit 773 (GRA) 3. Pin C, Circuit 776 (WHT) 4. Pin D, Circuit 772 (YEL) Or, a blank PRNDL display may also occur if an out of line condition exists with the Serial Data Circuit (CKT 2470, yellow wire) from the TCM to Splice Pack 205. Diagnostic Tip 1. Connect the Tech 2(R) to the vehicle. 2. Power up the Tech 2(R). 3. Does the Tech 2(R) communicate with the TCM? If not, inspect the serial data circuit, CKT 2470 (Yellow wire), between the TCM and Splice Pack 205. Specifically inspect connector C106, a five terminal connector located below the left side underhood bussed electrical center, directly beneath the red battery cable terminal connection. Perform a mating terminal pull test on all of the terminals in this connector. Repair as required. 4. Observe the Gear Selected screen on the scan tool. The following values should be shown on the Tech 2(R) display and the vehicle's instrument panel cluster (if equipped with the I/P display). ^ "8" (shifter should be in the Park position) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 1448 ^ "7" (shifter should be in the Reverse position) ^ "5" (shifter should be in the Drive position) ^ "3" (shifter should be in the Third gear position) ^ "2" (shifter should be in the Second gear position) ^ "1" (shifter should be in the First gear position) ^ "0" (shifter should be in the Neutral Position) If the Gear Selected display does not match the shifter position in the vehicle, diagnose using one of the following methods. ^ Obtain a new PNP switch kit, P/N 29540479, from the Parts Department. ^ 0.1. Disconnect the wiring connector from the original transmission mounted PNP switch. ^ 0.2. Connect the new switch to the wiring connector. ^ 0.3. Return to Step # 4 above and observe the display as you rotate the switch. If all positions indicate properly, refer to the Correction section below. ^ Use the DTC P0708 diagnostic chart in Service Information (SI) under Transmission/Transaxle/Automatic Transmission - Allison. Reference SI Document ID # 769549 for the wiring schematic for this symptom. The PNP switch, as referenced in SI, is known as the NSBU switch in the Parts information. It is now serviced with a Park Neutral Position Switch Kit, P/N 29540479. Flashing PRNDL Display A flashing PRNDL display may be the result of incorrect sensor inputs or transmission abuse protection modes being received by the TCM. The following are some of these conditions: ^ The transfer case is/was in Neutral. ^ The transfer case is/was shifted into Neutral when the vehicle is moving. ^ A decrease of the input turbine speed was not detected when the gear selector was moved into any gear. ^ A low transmission fluid level. ^ A misadjusted PNP/NSBU switch. ^ Turbine input speed or output speed sensor failure. ^ Failures of the shift solenoids to route the transmission oil to the proper clutch assemblies within the transmission. ^ Failures of the transmission clutch packs (C1 or C5 for first gear, C3 or C5 for Reverse). ^ Failure to detect proper line pressures when a gear range is selected, which may be the result of normal maintenance such as a transmission fluid change having been completed, or the transmission pan was removed for a filter replacement or other type service. Transmission abuse protection modes are encountered when a customer performs one of the following types of maneuvers: ^ Shifting from Neutral to Drive/Reverse when the engine RPM is greater than 1400 RPM. ^ Shifting from Drive to Reverse when the throttle position (TPS) is greater than 25%, such as rocking the vehicle when stuck in an attempt to free the vehicle. ^ When the transmission output speed is greater than 300 RPM from attempted changes in direction such as Reverse to Drive, Drive to Reverse or Neutral to Reverse shifts. When the TCM encounters any one of the above conditions, the TCM will flash the PRNDL and default the transmission to Neutral. A flashing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 1449 PRNDL indicates something is/was incorrect. The transmission may need the attention of a qualified service technician. Correction 1. Disconnect the wiring harness from the PNP switch. 2. Disconnect the shift linkage/cable from the shift lever at the transmission. 3. With a wrench keeping the shift lever from rotating, remove the nut from the end of the selector shaft. 4. Use a file to remove any burrs or raised metal where the selector lever was seated against the shoulder of the selector shaft. Important: If the old PNP switch will not slide from the selector shaft without the effort, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 5. Remove the two bolts that attach the PNP switch and remove the switch by sliding it outward over the selector shaft. 6. Make sure the selector shaft is in the N (neutral) position (using a wrench on the selector shaft flats, rotate the shaft to its furthest clockwise position and then rotate counterclockwise two detents). Important: If the new PNP switch will not slide onto the selector shaft easily, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 7. Slide the new PNP switch over the selector shaft with the neutral assurance bracket 920 facing outward and maintaining the correct PNP switch orientation to the selector shaft. Install and hand tighten the two PNP switch attaching bolts so that the PNP switch and bracket may be rotated within the adjusting slots with some effort. 8. While holding the neutral assurance bracket in engagement with the PNP switch, tighten the two bolts that attach the PNP switch to the transmission case. Tighten Tighten the bolts to 27 N.m (20 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 1450 9. Remove and discard the neutral assurance bracket. Important: Installation of the front shield and rear shields are important. Without proper installation of the shield, a return repair is probable. Follow all directions as listed on the installation instructions sheet included in the Switch kit, P/N 29540479. 10. Fit the new shield onto the PNP switch so that it fits securely against the switch. Make sure this is done before reinstalling the shift lever. 11. Reinstall the shift lever. With a wrench keeping the shift lever from rotating, install the nut on the end of the selector shaft. Tighten. Tighten the nut to 24 N.m (18 lb ft). 12. Connect the wiring harness connectors to the PNP switch. 13. Attach the selector cable to the lever. Check and adjust if needed. 14. Go back to step 4 of the Diagnostics and insure the Tech 2 readings match the shift lever positions. Important: Clear all DTCs before returning the vehicle to the customer. 15. Return the vehicle to the customer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 1451 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Slow/No Gear Engagement/Engine No Start Bulletin No.: 02-07-30-011C Date: June 21, 2004 TECHNICAL Subject: Slow or No Engagement of Automatic Transmission, No Start, Blank PRNDL Display, Flashing PRNDL, DTC P0708, P0872, P0847, P0875, P1711, P1713 or U1000 Set (Diagnose Condition, Repair According to Procedure) Models: 2001-2004 Chevrolet Silverado 2001-2004 GMC Sierra with Allison(R) LCT1000 Automatic Transmission (RPO M74) and 6.6L Duramax(TM) Diesel Engine (RPO LB7) or 8.1L Gas Engine (RPO L18) Supercede: This bulletin is being revised to add model years and additional model information and add graphics. Please discard Corporate Bulletin Number 02-07-30-011B (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions. ^ The PRNDL display is flashing. ^ The engine will not start. ^ The "Service Engine Soon" Indicator lamp is illuminated. ^ The transmission does not shift properly. ^ The vehicle will not move, transmission will not engage. Cause Moisture contamination within the Park Neutral Position (PNP) Switch may cause this condition. This is sometimes referred to as the Neutral Start Back-up (NSBU) Switch. On a left turn, water spray from the left front tire is directed directly at this switch. Proper installation of the "Front Shield" and "Rear Shield" are essential for proper repairs. Technician Diagnosis This bulletin ONLY applies to vehicles equipped with a two connector PNP switch as shown above. A complete and through diagnosis must be performed by a qualified electrical technician to determine the cause and avoid needless replacement of good components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 1457 Important: The Transmission Control Module (TCM) and or the Pressure Switch Manifold (PSM) should NOT be replaced unless properly diagnosed. They are probably not the cause of the concern. It is often assumed the module is the cause of the concern when, in fact, it is another component or the wiring between the components that causes the concern. Important: Remember, everything starts with a properly operating Neutral Start Back Up (NSBU) switch. The NSBU switch has been incorporated into what is now called the Park Neutral Position (PNP) switch. If the PNP switch does not provide the proper voltage signal to the module indicating the transmission is in either Park or Neutral, the module will not allow the starter operation. After the engine is started, and the shift lever is moved to either Reverse or one of the drive positions, the range selected portion of the PNP switch portion provides a voltage input to the module as to what range the driver has manually selected for transmission operation. The module then controls pressures, shift points and other transmission functions based on the voltage input received from the range portion of the PNP switch. The technician may find one or more of the following conditions. The list of these conditions does not imply any type of frequency or order. They are random events and may occur in any order. ^ DTC P0708, Neutral start/backup (PNP or NSBU) switch ^ DTC P0847, Pressure Switch Manifold (PSM) ^ DTC P0872, Pressure Switch Manifold (PSM) ^ DTC P0875, Pressure Switch Manifold (PSM) ^ DTC P1711, Pressure Switch Manifold (PSM) ^ DTC P1713, Pressure Switch Manifold (PSM) ^ DTC U1000, Serial Data Communications ^ Blank PRNDL Display ^ Flashing PRNDL Display ^ Slow or No Engagement of Automatic Transmission Blank PRNDL Display A blank PRNDL display may indicate a condition with the PNP switch and/or one or more of the four signal circuits from the PNP to the TCM. 1. Pin A, Circuit 771 (BLK/WHT) 2. Pin B, Circuit 773 (GRA) 3. Pin C, Circuit 776 (WHT) 4. Pin D, Circuit 772 (YEL) Or, a blank PRNDL display may also occur if an out of line condition exists with the Serial Data Circuit (CKT 2470, yellow wire) from the TCM to Splice Pack 205. Diagnostic Tip 1. Connect the Tech 2(R) to the vehicle. 2. Power up the Tech 2(R). 3. Does the Tech 2(R) communicate with the TCM? If not, inspect the serial data circuit, CKT 2470 (Yellow wire), between the TCM and Splice Pack 205. Specifically inspect connector C106, a five terminal connector located below the left side underhood bussed electrical center, directly beneath the red battery cable terminal connection. Perform a mating terminal pull test on all of the terminals in this connector. Repair as required. 4. Observe the Gear Selected screen on the scan tool. The following values should be shown on the Tech 2(R) display and the vehicle's instrument panel cluster (if equipped with the I/P display). ^ "8" (shifter should be in the Park position) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 1458 ^ "7" (shifter should be in the Reverse position) ^ "5" (shifter should be in the Drive position) ^ "3" (shifter should be in the Third gear position) ^ "2" (shifter should be in the Second gear position) ^ "1" (shifter should be in the First gear position) ^ "0" (shifter should be in the Neutral Position) If the Gear Selected display does not match the shifter position in the vehicle, diagnose using one of the following methods. ^ Obtain a new PNP switch kit, P/N 29540479, from the Parts Department. ^ 0.1. Disconnect the wiring connector from the original transmission mounted PNP switch. ^ 0.2. Connect the new switch to the wiring connector. ^ 0.3. Return to Step # 4 above and observe the display as you rotate the switch. If all positions indicate properly, refer to the Correction section below. ^ Use the DTC P0708 diagnostic chart in Service Information (SI) under Transmission/Transaxle/Automatic Transmission - Allison. Reference SI Document ID # 769549 for the wiring schematic for this symptom. The PNP switch, as referenced in SI, is known as the NSBU switch in the Parts information. It is now serviced with a Park Neutral Position Switch Kit, P/N 29540479. Flashing PRNDL Display A flashing PRNDL display may be the result of incorrect sensor inputs or transmission abuse protection modes being received by the TCM. The following are some of these conditions: ^ The transfer case is/was in Neutral. ^ The transfer case is/was shifted into Neutral when the vehicle is moving. ^ A decrease of the input turbine speed was not detected when the gear selector was moved into any gear. ^ A low transmission fluid level. ^ A misadjusted PNP/NSBU switch. ^ Turbine input speed or output speed sensor failure. ^ Failures of the shift solenoids to route the transmission oil to the proper clutch assemblies within the transmission. ^ Failures of the transmission clutch packs (C1 or C5 for first gear, C3 or C5 for Reverse). ^ Failure to detect proper line pressures when a gear range is selected, which may be the result of normal maintenance such as a transmission fluid change having been completed, or the transmission pan was removed for a filter replacement or other type service. Transmission abuse protection modes are encountered when a customer performs one of the following types of maneuvers: ^ Shifting from Neutral to Drive/Reverse when the engine RPM is greater than 1400 RPM. ^ Shifting from Drive to Reverse when the throttle position (TPS) is greater than 25%, such as rocking the vehicle when stuck in an attempt to free the vehicle. ^ When the transmission output speed is greater than 300 RPM from attempted changes in direction such as Reverse to Drive, Drive to Reverse or Neutral to Reverse shifts. When the TCM encounters any one of the above conditions, the TCM will flash the PRNDL and default the transmission to Neutral. A flashing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 1459 PRNDL indicates something is/was incorrect. The transmission may need the attention of a qualified service technician. Correction 1. Disconnect the wiring harness from the PNP switch. 2. Disconnect the shift linkage/cable from the shift lever at the transmission. 3. With a wrench keeping the shift lever from rotating, remove the nut from the end of the selector shaft. 4. Use a file to remove any burrs or raised metal where the selector lever was seated against the shoulder of the selector shaft. Important: If the old PNP switch will not slide from the selector shaft without the effort, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 5. Remove the two bolts that attach the PNP switch and remove the switch by sliding it outward over the selector shaft. 6. Make sure the selector shaft is in the N (neutral) position (using a wrench on the selector shaft flats, rotate the shaft to its furthest clockwise position and then rotate counterclockwise two detents). Important: If the new PNP switch will not slide onto the selector shaft easily, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 7. Slide the new PNP switch over the selector shaft with the neutral assurance bracket 920 facing outward and maintaining the correct PNP switch orientation to the selector shaft. Install and hand tighten the two PNP switch attaching bolts so that the PNP switch and bracket may be rotated within the adjusting slots with some effort. 8. While holding the neutral assurance bracket in engagement with the PNP switch, tighten the two bolts that attach the PNP switch to the transmission case. Tighten Tighten the bolts to 27 N.m (20 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 1460 9. Remove and discard the neutral assurance bracket. Important: Installation of the front shield and rear shields are important. Without proper installation of the shield, a return repair is probable. Follow all directions as listed on the installation instructions sheet included in the Switch kit, P/N 29540479. 10. Fit the new shield onto the PNP switch so that it fits securely against the switch. Make sure this is done before reinstalling the shift lever. 11. Reinstall the shift lever. With a wrench keeping the shift lever from rotating, install the nut on the end of the selector shaft. Tighten. Tighten the nut to 24 N.m (18 lb ft). 12. Connect the wiring harness connectors to the PNP switch. 13. Attach the selector cable to the lever. Check and adjust if needed. 14. Go back to step 4 of the Diagnostics and insure the Tech 2 readings match the shift lever positions. Important: Clear all DTCs before returning the vehicle to the customer. 15. Return the vehicle to the customer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 1461 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 1462 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 1463 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 1466 Transmission Position Switch/Sensor: Adjustments Automatic Transmission - Allison Park/Neutral Position Switch Adjustment ^ Tools Required J 41364-A PNP Switch Adjusting Tool Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Make sure the selector shaft is in the N (Neutral) position as follows: ^ Place a wrench on the selector shaft flats and rotate the shaft to its furthest clockwise position. ^ Rotate the selector shaft counter-clockwise two detents. 2. Be sure that J 41364-A (2) is in the proper position on PNP switch (1). 3. While maintaining the correct PNP switch-to-selector-shaft alignment, slide the new PNP switch (5) over the selector shaft (4). 4. Notice: Refer to Component Fastener Tightening Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 1467 While holding J 41364-A in engagement with the PNP switch, install the two bolts (6) so that the PNP switch may be rotated with some effort. ^ Tighten the two bolts (6) to 27 Nm (20 ft. lbs.). 5. Remove J 41364-A. 6. Install splash shield (1), concave side toward PNP switch (3), over selector shaft (2). 7. Notice: Refer to Transmission Selector Shaft Abuse Notice in Service Precautions. Reinstall Shift Lever (2). Install nut (3), by hand, on the end of selector shaft (4). Use a wrench (1) to keep the shift lever from rotating. ^ Tighten nut (3) to 24 Nm (18 ft. lbs.) 8. Reconnect the shift selector linkage/cable to the shift lever (2). 9. Connect the external wiring harness to the PNP switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L80-E/4L85-E Park/Neutral Position Switch Replacement Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 1470 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 1471 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 1472 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Park Lock Pawl and Actuator Replacement Park Lock Pawl and Actuator Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the park/neutral position (PNP) switch. 3. Remove the manual shaft nut and pin. 4. Remove the detent lever and actuator. 5. Remove the parking pawl bracket bolts. 6. Remove the parking pawl return spring. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 1473 7. Use the modified screw extractor in order to remove the plug. 8. Remove the parking pawl shaft retainer, shaft and pawl. 9. Important: If the manual shaft binds in the case during removal, file or sand the shaft in the area adjacent to the detent lever. Remove the manual shaft. 10. Remove the manual shaft seal. Installation Procedure 1. Install the pawl shaft. 2. Install the parking pawl. 3. Install the plug using a 8 mm or (5/16 inch) rod with Loctite® or equivalent. 4. Install the retainer. 5. Install the pawl return spring. 6. Install the detent lever to the actuator. 7. Install the actuator over the parking pawl. 8. Install the manual shaft seal. 9. Lubricate the manual shaft with transmission oil and install the manual shaft into the case. 10. Install the nut on the shaft. 11. Install the roll pin. 12. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 1474 Install the parking lock bracket bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 13. Install the PNP switch. 14. Install the transmission filter. 15. Fill the transmission to the proper level with Dexron® III transmission fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 1475 Transmission Position Switch/Sensor: Service and Repair Automatic Transmission - Allison Park/Neutral Position Switch Replacement PNP Switch Removal Refer to Park/Neutral Position Switch Removal. PNP Switch Install Refer to Park/Neutral Position Switch Installation. 7. Notice: Refer to Transmission Selector Shaft Abuse Notice in Service Precautions. Reinstall shift lever (2). Install nut (3), by hand, on the end of selector shaft (4). Use a wrench (1) to keep the shift lever from rotating. ^ Tighten nut (3) to 24 Nm (18 ft. lbs.). 8. Reconnect the shift selector linkage/cable to the shift lever (2). 9. Connect the external wiring harness to the PNP switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > A/T - Shifting/Poor Performance Vehicle Speed Sensor: Technical Service Bulletins A/T - Shifting/Poor Performance INFORMATION Bulletin No.: 01-03-10-010G Date: July 22, 2009 Subject: Inspection of Tire and Wheel Size Prior to Diagnosis of Transmission Shifts, Poor Performance, Speedometer, Cruise Control Concerns Models: 2001-2007 Chevrolet Silverado Pickup (Classic) Models Equipped with Allison(R) Automatic Transmission Only 2001-2007 GMC Sierra Pickup (Classic) Models Equipped with Allison(R) Automatic Transmission Only 2007-2010 Chevrolet Silverado Pickup HD Models 2007-2010 GMC Sierra Pickup HD Models Supercede: This bulletin is being revised to add the 2008-2010 model years, update the tire size information and reference the vehicle tire information label locations. Please discard Corporate Bulletin Number 01-03-10-010F (Section 03 - Suspension). GM has developed and matched specific tires for your vehicle. The original equipment tires and their respective size installed on the vehicle when it was new, were designed to meet General Motors Tire Performance Criteria Specification (TPC Spec) system rating. GM's exclusive TPC Spec system considers over a dozen critical specifications that impact the overall performance of the vehicle. A truck that has different tires and wheels from the original equipment designed for that vehicle will have engine power/performance concerns, transmission shift concerns, speedometer registered speed concerns, cruise control concerns and increased steering effort, especially during parking lot maneuvers at slow speeds. The engine control module (ECM) and transmission control module (TCM) use engine speed (RPM) and vehicle speed sensor (VSS) inputs as operational parameters for engine torque, transmission shifting, cruise control operation and speedometer indicated vehicle speed. Calibrations for different tire/wheel combinations are not available. Therefore, changing of tire and/or wheel size should not be undertaken by dealerships or truck owners. Proper diagnosis of engine, transmission, speedometer and cruise control concerns MUST begin with an inspection of tire/wheel size. Important A vehicle specific Tire and Loading Information label is attached to the center pillar (B-pillar) of the vehicle. With the driver's door open, you will find the label attached below the door lock post (striker). The label shows the size of the original equipment tires and the recommended cold tire inflation pressures.A vehicle specific Certification/Tire label is found on the rear edge of the driver's door. The label shows the size of the original equipment tires and the recommended cold tire inflation pressures. 2001-2007 Pickups (Classic) Equipped with Allison(R) Automatic Transmission Only Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT215/85R16D tires as standard equipment. 2007 Pickups HD Models (New Design Pickups) Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT215/85R16E tires as standard equipment. 2008-2010 Pickups HD Models (New Design Pickups) Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > A/T - Shifting/Poor Performance > Page 1480 - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT225/75R17E tires as standard equipment. If a truck is found to have other than the above listed tire sizes, no further diagnosis should be undertaken until the original size tires and wheels are reinstalled on the truck. Warranty Information Reinstalling the proper wheels and tires on the vehicle, prior to performing any type of diagnosis of the truck, would be considered truck owner responsibility and not a warranty repair. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Vehicle Speed Sensor (VSS) Vehicle Speed Sensor: Diagrams Vehicle Speed Sensor (VSS) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Vehicle Speed Sensor (VSS) > Page 1483 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Vehicle Speed Sensor (VSS) > Page 1484 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 Vehicle Speed Sensor: Service and Repair Manual Transmission - NV 3500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 1487 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and O-ring seal. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 1488 Vehicle Speed Sensor: Service and Repair Manual Transmission - NV 4500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (3). 3. Remove the VSS and seal. Installation Procedure 1. Coat the NEW O-ring seal with a thin film of transmission fluid, use GM P/N 12346190 (Canadian P/N 10953477), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 1489 3. Connect the VSS electrical connector (3). Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 1490 Vehicle Speed Sensor: Service and Repair Manual Transmission - ZF S6-650 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped with the 6.6L engine, disconnect the vehicle speed sensor (VSS) electrical connector (4). 3. If equipped with the 8.1L engine, disconnect the VSS electrical connector (5). 4. Remove the VSS bolt, sensor and seal. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 1491 1. Lubricate a NEW O-ring seal with transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). 3. If equipped with the 8.1L engine, connect the VSS electrical connector (5). 4. If equipped with the 6.6L engine, connect the VSS electrical connector (4). 5. Lower the vehicle. 6. Check the transmission fluid level. Add if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 1492 Vehicle Speed Sensor: Service and Repair Automatic Transmission - 4L60-E/4L65-E Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). 4. Notice: Refer to Fastener Notice in Service Precautions. Install the VSS bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 1493 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1498 Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1499 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SYSTEM DESCRIPTION The accelerator pedal position (APP) system along with the vehicle electronics and components is used to calculate and control the amount of acceleration and deceleration via fuel injector control. This eliminates the need for a mechanical cable attachment from the accelerator pedal to a throttle body. The APP system includes, but is not limited to, the following components : - The accelerator pedal position (APP) sensor assembly - The engine control module (ECM) Accelerator Pedal Position (APP) Sensor The accelerator pedal position (APP) sensor is mounted on the accelerator pedal control assembly. The sensor is made up of 3 individual sensors within one housing. Three separate signal, low reference, and 5-volt reference circuits are used in order to interface the accelerator pedal sensor assembly with the ECM. Each sensor has a unique functionality to determine pedal position. The ECM uses the APP sensor to determine the amount of acceleration or deceleration desired by the person driving the vehicle. The APP sensor 1 voltage should increase as the accelerator pedal is depressed, from below 1.0 volt at 0 pedal travel to above 2 volts at 100 percent pedal travel. APP sensor 2 voltage should decrease from above 4 volts at 0 pedal travel to below 3.0 volts at 100 percent pedal travel. APP sensor 3 voltage should decrease from above 3.8 volts at 0 percent pedal travel to below 3.3 volts at 100 percent pedal travel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1500 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION (APP) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector. 3. Reposition the carpet to access the lower nut. 4. Remove the accelerator pedal nuts. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1501 1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Service Precautions. 2. Install the accelerator pedal nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Connect the APP sensor electrical connector. 4. Reposition the carpet. 5. Install the CPA retainer. 6. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 7. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle and a wide open throttle (WOT). 8. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 9. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Mass Air Flow (MAF) Sensor: Locations Right Side Of The Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1505 Right Side Of Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1506 Intake Air Temperature (IAT)/Mass Airflow (MAF) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1507 Mass Air Flow (MAF) Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector (1). 2. Remove the MAF/IAT sensor TORX(R) screws. 3. Remove the MAF/IAT sensor (1). INSTALLATION PROCEDURE 1. Install the MAF/IAT sensor (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1508 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the MAF/IAT sensor TORX(R) screws. Tighten Tighten the screws to 8 N.m (70 lb in). 3. Connect the MAF/IAT sensor electrical connector (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations Fuel Temperature Sensor: Locations Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 1512 Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 1513 Fuel Temperature Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 1514 Fuel Temperature Sensor: Service and Repair FUEL RAIL TEMPERATURE (FRT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold cover. IMPORTANT: After removing the charged air cooler duct, cover the turbocharger openings with tape in order to prevent entry of objects. 2. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting. 3. Remove the charged air cooler inlet duct connector (4) from the turbocharger. 4. Disconnect the fuel temperature sensor electrical connector. 5. Remove the fuel temperature sensor. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 1515 1. Install the fuel temperature sensor. Tighten Tighten the sensor to 22 N.m (16 lb ft). 2. Connect the fuel temperature sensor electrical connector. 3. Remove the tape from the turbocharger openings. 4. Install the charged air cooler inlet duct connector (4) to the turbocharger. 5. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1). Tighten Tighten the clamp to 6 N.m (53 lb in). 6. Install the intake manifold cover. 7. Prime the fuel system. Refer to Fuel System Priming. 8. Start the engine. If the engine stalls, repeat the above step. 9. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations Turbo Boost Sensor: Locations Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Page 1519 Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Page 1520 Boost Pressure Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Page 1521 Turbo Boost Sensor: Service and Repair BOOST PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the right fuel rail fuel feed pipe. 2. Remove the boost sensor bracket bolt (1). 3. Remove the boost sensor and bracket. 4. Separate the boost sensor from the bracket. 5. Inspect the sensor seal for damage, replace as necessary. INSTALLATION PROCEDURE 1. Position the boost sensor onto the bracket. 2. Install the boost sensor and bracket. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the boost sensor bracket bolt (1). Tighten Tighten the bolt to 9 N.m (80 lb in). 4. Install the right fuel rail fuel feed pipe. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Right Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1526 Camshaft Position (CMP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Replacement CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the cooling fan pulley. 2. Remove the camshaft position (CMP) sensor bolt. 3. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Lubricate the CMP sensor O-ring with clean engine oil. 2. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the CMP sensor bolt. Tighten Tighten the bolt to 10 N.m (89 lb in). 4. Install the cooling fan pulley. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement > Page 1529 Camshaft Position Sensor: Service and Repair Camshaft Reluctor Replacement Camshaft Reluctor Replacement Removal Procedure Notice: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 1. Remove the engine front cover. 2. While holding the secondary oil pump shaft with a hex driver, remove the oil pump driven gear nut. 3. Remove the oil pump driven gear. 4. Important: DO NOT remove the reluctor from the oil pump drive gear. The reluctor is timed to the gear and once removed the correct timing will be lost. Remove the oil pump drive gear and crankshaft sensor reluctor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement > Page 1530 5. Remove the camshaft reluctor screws. 6. Remove the camshaft reluctor. 7. Clean and Inspect the camshaft reluctor for damage. Replace the reluctor if damage is found. Installation Procedure 1. Position the camshaft reluctor to the camshaft gear. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the camshaft reluctor bolts. Tighten the bolts to 9 Nm (80 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement > Page 1531 3. Important: Do not damage the teeth on the reluctor. Install the oil pump drive gear and reluctor to the crankshaft. 4. Install the oil pump driven gear. 5. While holding the secondary oil pump shaft with a hex driver, install the oil pump driven gear nut. Tighten the nut to 100 Nm (74 ft. lbs.). 6. Install the engine front cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Starter Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1535 Right Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1536 Crankshaft Position (CKP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1537 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the right wheelhouse panel. 3. Disconnect the crankshaft position (CKP) sensor electrical connector. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. 6. If necessary, remove the CKP sensor spacer bolts. 7. If necessary, remove the CKP sensor spacer. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1538 1. If necessary, lubricate a NEW CKP spacer O-ring with clean engine oil. 2. If necessary, install the NEW O-ring to the CKP sensor spacer. IMPORTANT: The crankshaft position sensor spacers are machined with different timing positions. However, if the crankshaft position sensor spacer requires replacement, replace with a grade "C" spacer. 3. If necessary, install the CKP sensor spacer. NOTE: Refer to Fastener Notice in Service Precautions. 4. If necessary, install the CKP sensor spacer bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). 5. Lubricate a NEW CKP sensor O-ring with clean engine oil. 6. Install the NEW O-ring to the CKP sensor. 7. Install the CKP sensor. 8. Install the CKP sensor bolt. Tighten Tighten the bolt to 10 N.m (89 lb in). 9. Connect the CKP sensor electrical connector. 10. Install the right wheelhouse panel. 11. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations Center of the I/P - Accessory Switches Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 1543 Inflatable Restraint I/P Module Disable Switch (With RPO Code C99) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Inflatable Restraint I/P Module Disable Switch (HD Model) Air Bag Deactivation Switch: Description and Operation Inflatable Restraint I/P Module Disable Switch (HD Model) INFLATABLE RESTRAINT I/P MODULE DISABLE SWITCH (HD MODEL PICKUPS) The instrument panel (I/P) module disable switch is a manual 2-position key switch. The I/P module disable switch allows the vehicle operator the ability to enable or disable the I/P module (passenger frontal air bag). The I/P module disable switch interfaces with the inflatable restraint sensing and diagnostic module (SDM) to request the enabling or disabling of the I/P module. The occupants are notified of the enabling or disabling of the I/P module via the I/P module disable switch ON/OFF indicators located on the I/P module disable switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Inflatable Restraint I/P Module Disable Switch (HD Model) > Page 1546 Air Bag Deactivation Switch: Description and Operation Inflatable Restraint I/P Module Disable Switch INFLATABLE RESTRAINT I/P MODULE DISABLE SWITCH The instrument panel (I/P) module disable switch is a manual 2-position key switch. The I/P module disable switch allows the vehicle operator the ability to enable or disable the I/P module (passenger frontal air bag). The I/P module disable switch interfaces with the passenger presence system (PPS) module to request the enabling or disabling of the I/P module. The occupants are notified of the enabling or disabling of the I/P module via the I/P module disable switch ON/OFF indicator and the PASSENGER AIR BAG ON/OFF indicators located on the rear view mirror. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Page 1547 Air Bag Deactivation Switch: Service and Repair INFLATABLE RESTRAINT INSTRUMENT PANEL (I/P) MODULE DISABLE SWITCH REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Service Precautions. 1. Remove the instrument panel trim bezel. 2. Remove the I/P module switch from the lower right opening of the switch plate panel. 3. Disconnect the I/P module switch electrical connector. INSTALLATION PROCEDURE 1. Connect the I/P module switch electrical connector. 2. Install the I/P module switch into the lower right opening of the switch plate panel. 3. Install the instrument panel trim bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations Front End Sensors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1551 Right Side Impact Sensor (With RPO Code HP2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1552 Impact Sensor: Diagrams Inflatable Restraint Front End Sensor - Left Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1553 Inflatable Restraint Front End Sensor - Right Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1554 Inflatable Restraint Front End Sensor (With RPO Code HVY) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1555 Inflatable Restraint Side Impact Sensor (SIS) - Right (With RPO Code HP2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Front End Sensors Impact Sensor: Description and Operation Front End Sensors INFLATABLE RESTRAINT FRONT END SENSORS The front end sensors are equipped on vehicles to supplement the SIR system performance. The front end sensors are electronic and are not part of the deployment loops, but instead provide inputs to the sensing and diagnostic module (SDM). The front end sensors can assist in determining the severity of some frontal collisions. The SDM uses the input from the front end sensors to assist in determining the severity of a frontal collision further supporting air bag deployment. If the SDM determines a deployment is warranted, the SDM will cause current to flow through the deployment loops deploying the frontal air bags. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Front End Sensors > Page 1558 Impact Sensor: Description and Operation Side Impact Sensor (SIS) (Right) With RPO HP2 INFLATABLE RESTRAINT SIDE IMPACT SENSOR (SIS) (RIGHT) WITH RPO HP2 The right side impact sensor (SIS) contains a sensing device which monitors vehicle acceleration and velocity changes to detect side collisions that are severe enough to warrant disabling the 42-volt system. The SIS is not part of the deployment loop, but instead provides an input to the sensing and diagnostic module (SDM). When the SDM receives a signal from the SIS that a collision has occurred, the SDM communicates this over the vehicles communication bus. The module responsible for the 42-volt system receives this message and disables the 42-volt system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Sensor: Service and Repair Front INFLATABLE RESTRAINT FRONT END SENSOR REPLACEMENT REMOVAL PROCEDURE CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1. 2. Disconnect the electrical connector. 3. Remove the connector position assurance (CPA) from the connector. 4. Remove the sensor bolt. 5. Remove the sensor (2) from the vehicle. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other contaminants from the mounting surface (1). IMPORTANT: Refer to SIR Service Precautions. 2. Point the arrow on the sensor toward the front of the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the sensor (2) horizontally to the radiator support. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 1561 Tighten Tighten the bolt to 9 N.m (79 lb in). 4. Connect the electrical connector to the sensor (2). 5. Install the CPA. 6. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 1562 Impact Sensor: Service and Repair Side INFLATABLE RESTRAINT SIDE IMPACT SENSOR REPLACEMENT REMOVAL PROCEDURE CAUTION: - Refer to SIR Inflator Module Handling and Storage Caution in Service Precautions. - When carrying an undeployed inflatable restraint seat belt pretensioner: - Do not carry the seat belt pretensioner by the wires or connector. - Carry the seat belt pretensioner by the piston tube, keeping hands and fingers away from the cable. - Make sure the open end of the seat belt pretensioner piston tube points away from you and other people. - Do not cover the seat belt pretensioner piston tube opening with your hand. Failure to observe these guidelines may result in personal injury. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 6. 2. Remove the front door trim panel. 3. Loosen the 2 inflatable restraint side impact sensor fasteners (2). 4. Remove the inflatable restraint side impact sensor (1) from the door (4). 5. Remove the connector position assurance (CPA) (3), and disconnect the inflatable restraint side impact sensor yellow 2-way harness connector (5). INSTALLATION PROCEDURE 1. Connect the inflatable restraint side impact sensor yellow 2-way harness connector (5) to the inflatable restraint side impact sensor (1). 2. Install the CPA (3) to the inflatable restraint side impact sensor yellow 2-way connector (5). 3. Install the inflatable restraint side impact sensor (1) to the door (4). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 1563 NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the fasteners (2) to the inflatable restraint side impact sensor (1) using only hand tools. Tighten Tighten the fasteners to 10 N.m (89 lb in). 5. Install the door trim panel. 6. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 6. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 1564 Impact Sensor: Service and Repair Sensor Replacement Guidelines SENSOR REPLACEMENT GUIDELINES The SIR sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. For example, a moderate collision where the front of the vehicle impacts a tree. If the vehicle has an SIR sensor mounted forward of the radiator, it must be replaced. - Replace the sensor whether or not the air bags have deployed. - Replace the sensor even if it appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR sensing system. Do not try to determine whether the sensor is undamaged, replace the sensor. Also, if you follow a Diagnostic Trouble Code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams Seat Belt Buckle Switch: Diagrams Seat Belt Switch - Driver Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Page 1568 Seat Belt Switch - Front Passenger (With RPO Code AL0) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-09-41-002A > Mar > 04 > SRS Air Bag Lamp ON/DTC B0092 Set Seat Occupant Sensor: Customer Interest SRS - Air Bag Lamp ON/DTC B0092 Set Bulletin No.: 02-09-41-002A Date: March 24, 2004 TECHNICAL Subject: Air Bag Lamp On, Passenger Air Bag Indicator Always Reads OFF, DTC B0092 Set (Repair Passenger Presence System (PPS) Sensor Harness) Models: 2003-2004 Cadillac Escalade, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon XL with Sensor Indicator Inflatable Restraint Front Passenger/Child Presence Detector (RPO ALO) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 02-09-41-002 (Section 09 - Restraints). Condition Some customers may comment that the Air Bag Lamp is on and the Passenger Air Bag indicator always reads OFF. Upon investigation, the technician may find DTC B0092 set. Cause The cause of this condition may be a shorted Passenger Presence System (PPS) sensor wire. The PPS sensor harness is located under the front passenger seat. This harness may be pinched between the seat frame and the track/riser. Correction Locate the PPS sensor (1) and inspect the harness for proper routing. If the harness is pinched between the seat frame and the track/riser, use the procedure listed below to repair wire(s). 1. Move the front passenger seat to the full rearward and full tilt up position. 2. Loosen the seat frame to track/riser nut and remove the harness. 3. Tighten the seat frame to track/riser nut. 4. Repair any damaged wires. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-09-41-002A > Mar > 04 > SRS Air Bag Lamp ON/DTC B0092 Set > Page 1577 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-50-009F > Dec > 10 > Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set Seat Occupant Sensor: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC B0092 Set Bulletin No.: 02-09-41-002A Date: March 24, 2004 TECHNICAL Subject: Air Bag Lamp On, Passenger Air Bag Indicator Always Reads OFF, DTC B0092 Set (Repair Passenger Presence System (PPS) Sensor Harness) Models: 2003-2004 Cadillac Escalade, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon XL with Sensor Indicator Inflatable Restraint Front Passenger/Child Presence Detector (RPO ALO) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 02-09-41-002 (Section 09 - Restraints). Condition Some customers may comment that the Air Bag Lamp is on and the Passenger Air Bag indicator always reads OFF. Upon investigation, the technician may find DTC B0092 set. Cause The cause of this condition may be a shorted Passenger Presence System (PPS) sensor wire. The PPS sensor harness is located under the front passenger seat. This harness may be pinched between the seat frame and the track/riser. Correction Locate the PPS sensor (1) and inspect the harness for proper routing. If the harness is pinched between the seat frame and the track/riser, use the procedure listed below to repair wire(s). 1. Move the front passenger seat to the full rearward and full tilt up position. 2. Loosen the seat frame to track/riser nut and remove the harness. 3. Tighten the seat frame to track/riser nut. 4. Repair any damaged wires. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set > Page 1587 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Occupant Sensor: > 05-06-04-043A > Aug > 05 > Fuel System/Body - Fuel Filler Cap Tether Too Short Fuel Filler Cap: All Technical Service Bulletins Fuel System/Body - Fuel Filler Cap Tether Too Short Bulletin No.: 05-06-04-043A Date: August 02, 2005 TECHNICAL Subject: Fuel Cap Tether Too Short to Hook On Fuel Door While Fueling Vehicle (Install Fuel Filler Housing and Cap) Models: 2004-2005 Cadillac Escalade Models 2004-2005 Chevrolet Silverado, Suburban, Tahoe Models 2004-2005 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to correct the fuel filler cap P/N. P/N 15225006 is released for 2006 and 2007 model year vehicles only. The correct fuel cap for the 2004 and 2005 model year is P/N 15225005. Dealers who currently have P/N 15225006 on order (possibly back-ordered) for this concern should cancel their order and re-order P/N 15225005. Please discard Corporate Bulletin Number 05-06-04-043 (Section 06 - Engine/Propulsion System). Built Prior to the VIN Breakpoints shown. Condition Some customers may comment that the fuel cap tether is too short to hook on the fuel door while fueling the vehicle. Cause The existing fuel cap tether is too short. The existing fuel filler housing elongated hole is too small to accommodate the new fuel cap tether. Correction Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Occupant Sensor: > 05-06-04-043A > Aug > 05 > Fuel System/Body - Fuel Filler Cap Tether Too Short > Page 1593 Important: Clean the fuel filler cap and surrounding areas prior to removing the fuel filler housing in order to avoid possible contamination. 1. Remove the fuel fill cap. 2. Remove the fuel tank filler housing to fuel tank fill pipe screws. 3. Remove the fuel tank filler housing to body TORX® screws (1) and retainer (2). Important: It is NOT necessary to raise the vehicle in order to remove and/or install the fuel filler housing. 4. Remove the fuel filler housing from under the vehicle. 5. Install the new fuel filler housing, P/N 15289921, from under the vehicle. 6. Install the fuel tank filler housing to fuel tank fill pipe screws. Tighten Tighten the screws to 2.3 N.m (20 lb in). 7. Install the fuel tank filler housing to body TORX(R) screws and retainer. Tighten Tighten the screws to 2.3 N.m (20 lb in). Important: The new fuel cap, P/N 15225005 "tether strap" installs in the elongated hole in the fuel filler housing. DO NOT install the new fuel cap tether in the round hole in the fuel filler housing. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Occupant Sensor: > 05-06-04-043A > Aug > 05 > Fuel System/Body - Fuel Filler Cap Tether Too Short > Page 1594 8. Install the new fuel cap, P/N 15225005, tether strap in the elongated hole in the fuel filler housing. 9. Install the fuel fill cap on the filler pipe and tighten until the cap clicks. Parts Information Warranty Information For vehicles repaired under warranty, use the table Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Occupant Sensor: > 05-06-04-043A > Aug > 05 > Fuel System/Body - Fuel Filler Cap Tether Too Short > Page 1600 Important: Clean the fuel filler cap and surrounding areas prior to removing the fuel filler housing in order to avoid possible contamination. 1. Remove the fuel fill cap. 2. Remove the fuel tank filler housing to fuel tank fill pipe screws. 3. Remove the fuel tank filler housing to body TORX® screws (1) and retainer (2). Important: It is NOT necessary to raise the vehicle in order to remove and/or install the fuel filler housing. 4. Remove the fuel filler housing from under the vehicle. 5. Install the new fuel filler housing, P/N 15289921, from under the vehicle. 6. Install the fuel tank filler housing to fuel tank fill pipe screws. Tighten Tighten the screws to 2.3 N.m (20 lb in). 7. Install the fuel tank filler housing to body TORX(R) screws and retainer. Tighten Tighten the screws to 2.3 N.m (20 lb in). Important: The new fuel cap, P/N 15225005 "tether strap" installs in the elongated hole in the fuel filler housing. DO NOT install the new fuel cap tether in the round hole in the fuel filler housing. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Occupant Sensor: > 05-06-04-043A > Aug > 05 > Fuel System/Body - Fuel Filler Cap Tether Too Short > Page 1601 8. Install the new fuel cap, P/N 15225005, tether strap in the elongated hole in the fuel filler housing. 9. Install the fuel fill cap on the filler pipe and tighten until the cap clicks. Parts Information Warranty Information For vehicles repaired under warranty, use the table Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations Passenger Presence Components - Under Front Passenger Seat Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 1605 Seat Sensor/Switch: Diagrams Inflatable Restraint Seat Position Switch - Left (With RPO Code AL0) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 1606 Inflatable Restraint Seat Position Switch - Right ((With RPO Code AL0) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 1607 Seat Sensor/Switch: Service and Repair INFLATABLE RESTRAINT SEAT POSITION SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the passenger or driver's seat from the vehicle. 2. Disconnect the electrical connector from the seat position sensor. CAUTION: Eye protection must be worn when drilling rivets to reduce the chance of personal injury. 3. Drill out the rivets that retain the seat position sensor (1) to the seat adjuster track bracket. 4. Remove the seat position sensor from the seat adjuster track bracket. INSTALLATION PROCEDURE 1. Install the seat position sensor to the seat adjuster bracket. 2. Install the rivets that retain the seat position sensor (1) to the seat adjuster track bracket. 3. Connect the electrical connector to the seat position sensor. 4. Install the passenger or driver's seat to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams Clutch Start Switch (M/T) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Rear Wheel Steering Switch > Component Information > Service and Repair Rear Wheel Steering Switch: Service and Repair Rear Wheel Steering Mode Switch Replacement Removal Procedure 1. Remove the dash trim bezel. 2. Grasp the rear wheel steering mode switch housing (2) and pull outward to remove the switch assembly. 3. Disconnect the electrical connector (3) from the rear wheel steering mode switch. 4. Remove the rear wheel steering mode switch assembly (1) from the vehicle. Installation Procedure 1. Reconnect the rear wheel steering mode switch (3) electrical connectors. 2. Install the rear wheel steering mode switch (1) into the dash. 3. Reinstall the dash trim bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Rear Position Sensor Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the steering gear protection shield (1) retaining bolts (3). 3. Disconnect the electrical connector (1). 4. Notice: When removing the rear position cover from the steering gear be careful not to damage to the rear position sensor. Remove the rear wheel position sensor cover (4) from the steering gear by prying on the cover using the slot. 5. Remove the rear wheel position sensor retaining bolts (3). 6. Important: Check the inner tie rod boot for wear or damage. If the boots are damaged replace the steering gear actuator. 7. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Page 1620 Maintain the sensor position. Do not turn the sensor. Remove the rear wheel position sensor (2) from the steering gear. Installation Procedure 1. Important: Make sure the O-ring (1) is installed. Install the rear wheel position sensor (2) to the steering gear. 2. Important: Be careful to maintain the position of the replacement sensor. Remove the pin retaining the position of the new sensor and immediately install the sensor to the steering gear. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear wheel position sensor retaining bolts. Apply LOCTITE 242 blue. ^ Tighten the bolts to 4 Nm (35 inch lbs.). 4. Install the rear wheel position sensor cover (4). 5. Connect the electrical connector (1). 6. Install the steering gear protection shield (1) and retaining bolts (3). ^ Tighten the steering gear protection shield retaining bolts to 180 Nm (132 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Page 1621 7. Lower the vehicle. 8. Perform a four wheel alignment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Column Position Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement (Centering Required) ^ Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure 1. Set the front wheels in the straight-ahead position. 2. Install J 42640 or set the steering wheel in the LOCKED position. 3. Caution: Refer to SIR Caution in Service Precautions. Disconnect the negative battery cable. 4. Disable the SIR. 5. Important: You MUST make an alignment mark on the upper intermediate shaft to the steering column shaft, where they connect. You will need the alignment marks for installation. Make an alignment mark on the upper intermediate shaft and the steering column shaft, where they connect, before removal. 6. Remove the nut and the bolt from the upper to the lower steering shaft connection. Slide the lower shaft down. 7. Remove the steering wheel position sensor connector by using a suitable tool in order to pull the connector down around the right side of the steering column for accessibility. 8. Important: Do not apply force to the steering wheel position sensor and the adapter and bearing assembly in a sideways direction. If reusing the existing steering wheel position sensor, it MUST be centered before removal. Verify the type of steering wheel position sensor before removal. Refer to Steering Wheel Position Sensor Centering. 9. Remove the steering wheel position sensor and adapter and bearing assembly from the steering column jacket by pulling the assembly straight out. 10. Remove the steering wheel position sensor from the clips in the adapter and bearing assembly. Installation Procedure 1. Important: A new sensor MUST come with a pin installed. If pin is not installed, return and reorder sensor. Verify the following before installing the steering wheel position sensor: ^ The front wheels are in the straight-ahead position. ^ That J 42640 is installed or the steering wheel is in the LOCKED position. 2. If reusing the existing steering wheel position sensor, verify the type of sensor you have before installing. Refer to Steering Wheel Position Sensor Centering. 3. Install the steering wheel position sensor into the adapter and bearing assembly. 4. Install the adapter and bearing assembly into the steering column jacket. 1. Align the notches on the adapter and bearing assembly and the steering column jacket. 2. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 1626 Do not apply force to the steering wheel position sensor and the adapter and bearing assembly in a sideways direction. Seat the adapter and bearing assembly into the steering column jacket. 5. Connect the steering wheel position sensor connector. 6. Notice: Refer to Fastener Notice in Service Precautions. Align the marks on the upper intermediate shaft and the steering column shafts, where they connect, that you made during the removal procedure. 7. Install the intermediate shaft to the steering column pinch bolt. ^ Tighten the nut to 62 Nm (46 ft. lbs.). 8. Connect the negative battery cable. 9. Enable the SIR system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 1627 Steering Column Position Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure 1. Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. 3. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) 7. Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 1628 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note location of the pin hole. ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin. Note the location of the pin hole. ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 1629 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure 1. Important: If reusing the existing sensor, no centering of the sensor is required. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right.From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin. Note the location of the pin hole. ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 1630 ^ A foam ring (3) ^ An alignment tab (2) for installing into the adapter and bearing assembly ^ A view of the inside of the connector 7. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin. Note location of the pin hole. ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 11. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 15. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 1631 until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 19. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin. Note location of the pin hole. ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 23. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 1632 Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 1633 Steering Column Position Sensor: Service and Repair Inflatable Restraint Steering Wheel Module Coil Centering Inflatable Restraint Steering Wheel Module Coil Centering 1. Notice: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction. Important: If double wire harness strap is installed onto the wire harness assembly and column, you must reuse the holder for the wire straps during installation. Remove the wire harness strap(s) where necessary. Verify the following conditions before centering the SIR coil: ^ The wheels on the vehicle are straight ahead. ^ The block tooth (1) of the steering shaft assembly is in the 12 o'clock position. ^ The ignition switch is in the LOCK position. 2. If the front (5) of the SIR coil has a centering window (4), and the back side (2) includes a spring service lock (1), perform the following steps: 1. Hold the SIR coil with the face up. 2. While depressing the spring service lock, rotate the coil hub clockwise until the coil ribbon stops. 3. Rotate the coil hub slowly, counterclockwise, until the centering window appears yellow and both arrows (3) line up. 4. Release spring service lock between the locking tab. The SIR coil is now centered. 5. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 3. If the front (4) of the SIR coil has a centering window (3), and the back side (1) includes NO spring service lock, perform the following steps: 0. Hold the SIR coil with the face up. 1. Rotate the coil hub clockwise until the coil ribbon stops. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 1634 2. Rotate the coil hub slowly, counterclockwise until the centering window appears yellow and both arrows (2) line up. This is the CENTER position. 3. While holding the coil hub in the CENTER position, align the SIR coil with the horn tower and slide onto the steering shaft assembly. 4. If the front side (3) of the SIR coil has NO centering window, but the back side (2) includes a spring service lock (1), perform the following steps: 0. Hold the SIR coil with the back side up. 1. While depressing the spring service lock, rotate the coil hub in the direction of the arrow (4) until the coil ribbon stops. 2. Still pressing the spring service lock, rotate the coil hub in the opposite direction 21⁄2 revolutions. 3. Release the spring service lock between locking tabs. The SIR coil is now centered. 4. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 5. If the front side (2) of the SIR coil has NO centering window, and the back side (1) includes NO spring service lock, perform the following steps: 0. Hold the SIR coil with the face up. 1. Rotate the coil hub in the direction of the arrow until the coil ribbon stops. 2. Rotate the coil hub, slowly, counterclockwise, for 21⁄2 revolutions. This is the CENTER position. 3. While maintaining the coil hub in the CENTER position, align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 6. If double wire harness strap is installed onto the wire harness assembly and column, you must route the wires up against the steering column. One wire harness strap will surround one lead from the coil to the steering column. The other wire harness strap will surround all leads to the steering column. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Rear Position Sensor Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the steering gear protection shield (1) retaining bolts (3). 3. Disconnect the electrical connector (1). 4. Notice: When removing the rear position cover from the steering gear be careful not to damage to the rear position sensor. Remove the rear wheel position sensor cover (4) from the steering gear by prying on the cover using the slot. 5. Remove the rear wheel position sensor retaining bolts (3). 6. Important: Check the inner tie rod boot for wear or damage. If the boots are damaged replace the steering gear actuator. 7. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Page 1639 Maintain the sensor position. Do not turn the sensor. Remove the rear wheel position sensor (2) from the steering gear. Installation Procedure 1. Important: Make sure the O-ring (1) is installed. Install the rear wheel position sensor (2) to the steering gear. 2. Important: Be careful to maintain the position of the replacement sensor. Remove the pin retaining the position of the new sensor and immediately install the sensor to the steering gear. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear wheel position sensor retaining bolts. Apply LOCTITE 242 blue. ^ Tighten the bolts to 4 Nm (35 inch lbs.). 4. Install the rear wheel position sensor cover (4). 5. Connect the electrical connector (1). 6. Install the steering gear protection shield (1) and retaining bolts (3). ^ Tighten the steering gear protection shield retaining bolts to 180 Nm (132 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Page 1640 7. Lower the vehicle. 8. Perform a four wheel alignment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair Suspension Mode Switch: Service and Repair Electronic Suspension Ride Control Switch Replacement Removal Procedure 1. Remove the instrument panel trim bezel. 2. Remove the switch from the lower opening of the switch plate panel. 3. Disconnect the electrical connector. Installation Procedure 1. Connect the electrical connector. 2. Install the switch into the lower opening of the switch plate panel. 3. Install the instrument panel trim bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1649 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions Brake Switch - TCC: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1656 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1657 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1658 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1659 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1660 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1661 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1662 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1663 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1664 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1665 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1666 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1667 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1668 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1669 Brake Switch - TCC: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1670 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1671 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1672 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1673 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1674 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1675 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1676 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1677 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1678 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1679 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1680 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1681 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1682 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1683 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1684 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1685 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1686 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1687 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1688 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1689 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1690 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1691 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1692 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1693 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1694 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1695 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1696 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1697 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1698 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1699 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1700 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1701 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1702 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1703 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1704 Power, Ground and Brake Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Component Locations Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Component Locations > Page 1709 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 1710 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 1711 Fluid Pressure Sensor/Switch: Service and Repair Pressure Switch Manifold Replacement Removal Procedure 1. Important: Individual pressure switches cannot be replaced. When any pressure switch needs replacing, the entire assembly must be replaced. Important: The G solenoid has been removed for clarity. Remove the oil pan and suction filter. 2. Remove the two bolts (2). Remove the reverse signal tube (1). 3. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the internal wiring harness connector from the pressure switch assembly (2). 4. Remove five bolts (1). Remove the pressure switch assembly (2). Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 1712 1. Notice: Refer to Fastener Notice in Service Precautions. Place the new pressure switch manifold assembly (2) in position and install one bolt (1) in a recessed location to hold it into position. Start the remaining four bolts (1) in recessed locations and tighten the bolts by hand. Torque the bolts to 12 Nm (108 inch lbs.). 2. Connect the internal wiring harness connector to the pressure switch assembly. 3. Install the reverse signal tube (1). Install two bolts (2). ^ Tighten the bolts to 12 Nm (108 inch lbs.). 4. Install the oil pan and suction filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission Valve Clearance: Adjustments Valve Clearance Adjustment 1. Remove the fan clutch. 2. Remove the upper valve rocker arm covers. 3. Rotate the crankshaft in order to bring the number 1 cylinder to Top Dead Center (TDC) of the compression stroke. The number 1 cylinder is the front cylinder on the right bank. The mark on the crankshaft balancer should be aligned with the mark on the engine. 4. Loosen the valve adjusting screws. 5. Insert a feeler gauge between the tip of the rocker arm and the valve bridge. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 1717 6. Adjust the valve lash to 0.3 mm (0.012 inch). Refer to Valve Clearance Adjustment Specifications to determine which valves can be adjusted when the engine is at TDC. Notice: Refer to Fastener Notice in Service Precautions. 7. Tighten the lock nut. Tighten nut to 22 Nm (16 ft. lbs.). 8. Rotate the crankshaft one revolution in order to bring the number 1 cylinder to TDC of the exhaust stroke. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 1718 9. Loosen the valve adjusting screws. 10. Insert a feeler gage between the tip of the rocker arm and the valve bridge. 11. Adjust the valve clearance to 0.3 mm (0.0112 inch). Refer to Valve Clearance Adjustment Specifications to determine which valves can be adjusted when the engine is at TDC. 12. Tighten the lock nut. Tighten nut to 22 Nm (16 ft. lbs.). 13. Install the upper valve rocker arm covers. 14. Install the fan clutch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 1719 Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start Transmission Position Switch/Sensor: Customer Interest A/T - Slow/No Gear Engagement/Engine No Start Bulletin No.: 02-07-30-011C Date: June 21, 2004 TECHNICAL Subject: Slow or No Engagement of Automatic Transmission, No Start, Blank PRNDL Display, Flashing PRNDL, DTC P0708, P0872, P0847, P0875, P1711, P1713 or U1000 Set (Diagnose Condition, Repair According to Procedure) Models: 2001-2004 Chevrolet Silverado 2001-2004 GMC Sierra with Allison(R) LCT1000 Automatic Transmission (RPO M74) and 6.6L Duramax(TM) Diesel Engine (RPO LB7) or 8.1L Gas Engine (RPO L18) Supercede: This bulletin is being revised to add model years and additional model information and add graphics. Please discard Corporate Bulletin Number 02-07-30-011B (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions. ^ The PRNDL display is flashing. ^ The engine will not start. ^ The "Service Engine Soon" Indicator lamp is illuminated. ^ The transmission does not shift properly. ^ The vehicle will not move, transmission will not engage. Cause Moisture contamination within the Park Neutral Position (PNP) Switch may cause this condition. This is sometimes referred to as the Neutral Start Back-up (NSBU) Switch. On a left turn, water spray from the left front tire is directed directly at this switch. Proper installation of the "Front Shield" and "Rear Shield" are essential for proper repairs. Technician Diagnosis This bulletin ONLY applies to vehicles equipped with a two connector PNP switch as shown above. A complete and through diagnosis must be performed by a qualified electrical technician to determine the cause and avoid needless replacement of good components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 1728 Important: The Transmission Control Module (TCM) and or the Pressure Switch Manifold (PSM) should NOT be replaced unless properly diagnosed. They are probably not the cause of the concern. It is often assumed the module is the cause of the concern when, in fact, it is another component or the wiring between the components that causes the concern. Important: Remember, everything starts with a properly operating Neutral Start Back Up (NSBU) switch. The NSBU switch has been incorporated into what is now called the Park Neutral Position (PNP) switch. If the PNP switch does not provide the proper voltage signal to the module indicating the transmission is in either Park or Neutral, the module will not allow the starter operation. After the engine is started, and the shift lever is moved to either Reverse or one of the drive positions, the range selected portion of the PNP switch portion provides a voltage input to the module as to what range the driver has manually selected for transmission operation. The module then controls pressures, shift points and other transmission functions based on the voltage input received from the range portion of the PNP switch. The technician may find one or more of the following conditions. The list of these conditions does not imply any type of frequency or order. They are random events and may occur in any order. ^ DTC P0708, Neutral start/backup (PNP or NSBU) switch ^ DTC P0847, Pressure Switch Manifold (PSM) ^ DTC P0872, Pressure Switch Manifold (PSM) ^ DTC P0875, Pressure Switch Manifold (PSM) ^ DTC P1711, Pressure Switch Manifold (PSM) ^ DTC P1713, Pressure Switch Manifold (PSM) ^ DTC U1000, Serial Data Communications ^ Blank PRNDL Display ^ Flashing PRNDL Display ^ Slow or No Engagement of Automatic Transmission Blank PRNDL Display A blank PRNDL display may indicate a condition with the PNP switch and/or one or more of the four signal circuits from the PNP to the TCM. 1. Pin A, Circuit 771 (BLK/WHT) 2. Pin B, Circuit 773 (GRA) 3. Pin C, Circuit 776 (WHT) 4. Pin D, Circuit 772 (YEL) Or, a blank PRNDL display may also occur if an out of line condition exists with the Serial Data Circuit (CKT 2470, yellow wire) from the TCM to Splice Pack 205. Diagnostic Tip 1. Connect the Tech 2(R) to the vehicle. 2. Power up the Tech 2(R). 3. Does the Tech 2(R) communicate with the TCM? If not, inspect the serial data circuit, CKT 2470 (Yellow wire), between the TCM and Splice Pack 205. Specifically inspect connector C106, a five terminal connector located below the left side underhood bussed electrical center, directly beneath the red battery cable terminal connection. Perform a mating terminal pull test on all of the terminals in this connector. Repair as required. 4. Observe the Gear Selected screen on the scan tool. The following values should be shown on the Tech 2(R) display and the vehicle's instrument panel cluster (if equipped with the I/P display). ^ "8" (shifter should be in the Park position) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 1729 ^ "7" (shifter should be in the Reverse position) ^ "5" (shifter should be in the Drive position) ^ "3" (shifter should be in the Third gear position) ^ "2" (shifter should be in the Second gear position) ^ "1" (shifter should be in the First gear position) ^ "0" (shifter should be in the Neutral Position) If the Gear Selected display does not match the shifter position in the vehicle, diagnose using one of the following methods. ^ Obtain a new PNP switch kit, P/N 29540479, from the Parts Department. ^ 0.1. Disconnect the wiring connector from the original transmission mounted PNP switch. ^ 0.2. Connect the new switch to the wiring connector. ^ 0.3. Return to Step # 4 above and observe the display as you rotate the switch. If all positions indicate properly, refer to the Correction section below. ^ Use the DTC P0708 diagnostic chart in Service Information (SI) under Transmission/Transaxle/Automatic Transmission - Allison. Reference SI Document ID # 769549 for the wiring schematic for this symptom. The PNP switch, as referenced in SI, is known as the NSBU switch in the Parts information. It is now serviced with a Park Neutral Position Switch Kit, P/N 29540479. Flashing PRNDL Display A flashing PRNDL display may be the result of incorrect sensor inputs or transmission abuse protection modes being received by the TCM. The following are some of these conditions: ^ The transfer case is/was in Neutral. ^ The transfer case is/was shifted into Neutral when the vehicle is moving. ^ A decrease of the input turbine speed was not detected when the gear selector was moved into any gear. ^ A low transmission fluid level. ^ A misadjusted PNP/NSBU switch. ^ Turbine input speed or output speed sensor failure. ^ Failures of the shift solenoids to route the transmission oil to the proper clutch assemblies within the transmission. ^ Failures of the transmission clutch packs (C1 or C5 for first gear, C3 or C5 for Reverse). ^ Failure to detect proper line pressures when a gear range is selected, which may be the result of normal maintenance such as a transmission fluid change having been completed, or the transmission pan was removed for a filter replacement or other type service. Transmission abuse protection modes are encountered when a customer performs one of the following types of maneuvers: ^ Shifting from Neutral to Drive/Reverse when the engine RPM is greater than 1400 RPM. ^ Shifting from Drive to Reverse when the throttle position (TPS) is greater than 25%, such as rocking the vehicle when stuck in an attempt to free the vehicle. ^ When the transmission output speed is greater than 300 RPM from attempted changes in direction such as Reverse to Drive, Drive to Reverse or Neutral to Reverse shifts. When the TCM encounters any one of the above conditions, the TCM will flash the PRNDL and default the transmission to Neutral. A flashing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 1730 PRNDL indicates something is/was incorrect. The transmission may need the attention of a qualified service technician. Correction 1. Disconnect the wiring harness from the PNP switch. 2. Disconnect the shift linkage/cable from the shift lever at the transmission. 3. With a wrench keeping the shift lever from rotating, remove the nut from the end of the selector shaft. 4. Use a file to remove any burrs or raised metal where the selector lever was seated against the shoulder of the selector shaft. Important: If the old PNP switch will not slide from the selector shaft without the effort, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 5. Remove the two bolts that attach the PNP switch and remove the switch by sliding it outward over the selector shaft. 6. Make sure the selector shaft is in the N (neutral) position (using a wrench on the selector shaft flats, rotate the shaft to its furthest clockwise position and then rotate counterclockwise two detents). Important: If the new PNP switch will not slide onto the selector shaft easily, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 7. Slide the new PNP switch over the selector shaft with the neutral assurance bracket 920 facing outward and maintaining the correct PNP switch orientation to the selector shaft. Install and hand tighten the two PNP switch attaching bolts so that the PNP switch and bracket may be rotated within the adjusting slots with some effort. 8. While holding the neutral assurance bracket in engagement with the PNP switch, tighten the two bolts that attach the PNP switch to the transmission case. Tighten Tighten the bolts to 27 N.m (20 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 1731 9. Remove and discard the neutral assurance bracket. Important: Installation of the front shield and rear shields are important. Without proper installation of the shield, a return repair is probable. Follow all directions as listed on the installation instructions sheet included in the Switch kit, P/N 29540479. 10. Fit the new shield onto the PNP switch so that it fits securely against the switch. Make sure this is done before reinstalling the shift lever. 11. Reinstall the shift lever. With a wrench keeping the shift lever from rotating, install the nut on the end of the selector shaft. Tighten. Tighten the nut to 24 N.m (18 lb ft). 12. Connect the wiring harness connectors to the PNP switch. 13. Attach the selector cable to the lever. Check and adjust if needed. 14. Go back to step 4 of the Diagnostics and insure the Tech 2 readings match the shift lever positions. Important: Clear all DTCs before returning the vehicle to the customer. 15. Return the vehicle to the customer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 1732 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Slow/No Gear Engagement/Engine No Start Bulletin No.: 02-07-30-011C Date: June 21, 2004 TECHNICAL Subject: Slow or No Engagement of Automatic Transmission, No Start, Blank PRNDL Display, Flashing PRNDL, DTC P0708, P0872, P0847, P0875, P1711, P1713 or U1000 Set (Diagnose Condition, Repair According to Procedure) Models: 2001-2004 Chevrolet Silverado 2001-2004 GMC Sierra with Allison(R) LCT1000 Automatic Transmission (RPO M74) and 6.6L Duramax(TM) Diesel Engine (RPO LB7) or 8.1L Gas Engine (RPO L18) Supercede: This bulletin is being revised to add model years and additional model information and add graphics. Please discard Corporate Bulletin Number 02-07-30-011B (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions. ^ The PRNDL display is flashing. ^ The engine will not start. ^ The "Service Engine Soon" Indicator lamp is illuminated. ^ The transmission does not shift properly. ^ The vehicle will not move, transmission will not engage. Cause Moisture contamination within the Park Neutral Position (PNP) Switch may cause this condition. This is sometimes referred to as the Neutral Start Back-up (NSBU) Switch. On a left turn, water spray from the left front tire is directed directly at this switch. Proper installation of the "Front Shield" and "Rear Shield" are essential for proper repairs. Technician Diagnosis This bulletin ONLY applies to vehicles equipped with a two connector PNP switch as shown above. A complete and through diagnosis must be performed by a qualified electrical technician to determine the cause and avoid needless replacement of good components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 1738 Important: The Transmission Control Module (TCM) and or the Pressure Switch Manifold (PSM) should NOT be replaced unless properly diagnosed. They are probably not the cause of the concern. It is often assumed the module is the cause of the concern when, in fact, it is another component or the wiring between the components that causes the concern. Important: Remember, everything starts with a properly operating Neutral Start Back Up (NSBU) switch. The NSBU switch has been incorporated into what is now called the Park Neutral Position (PNP) switch. If the PNP switch does not provide the proper voltage signal to the module indicating the transmission is in either Park or Neutral, the module will not allow the starter operation. After the engine is started, and the shift lever is moved to either Reverse or one of the drive positions, the range selected portion of the PNP switch portion provides a voltage input to the module as to what range the driver has manually selected for transmission operation. The module then controls pressures, shift points and other transmission functions based on the voltage input received from the range portion of the PNP switch. The technician may find one or more of the following conditions. The list of these conditions does not imply any type of frequency or order. They are random events and may occur in any order. ^ DTC P0708, Neutral start/backup (PNP or NSBU) switch ^ DTC P0847, Pressure Switch Manifold (PSM) ^ DTC P0872, Pressure Switch Manifold (PSM) ^ DTC P0875, Pressure Switch Manifold (PSM) ^ DTC P1711, Pressure Switch Manifold (PSM) ^ DTC P1713, Pressure Switch Manifold (PSM) ^ DTC U1000, Serial Data Communications ^ Blank PRNDL Display ^ Flashing PRNDL Display ^ Slow or No Engagement of Automatic Transmission Blank PRNDL Display A blank PRNDL display may indicate a condition with the PNP switch and/or one or more of the four signal circuits from the PNP to the TCM. 1. Pin A, Circuit 771 (BLK/WHT) 2. Pin B, Circuit 773 (GRA) 3. Pin C, Circuit 776 (WHT) 4. Pin D, Circuit 772 (YEL) Or, a blank PRNDL display may also occur if an out of line condition exists with the Serial Data Circuit (CKT 2470, yellow wire) from the TCM to Splice Pack 205. Diagnostic Tip 1. Connect the Tech 2(R) to the vehicle. 2. Power up the Tech 2(R). 3. Does the Tech 2(R) communicate with the TCM? If not, inspect the serial data circuit, CKT 2470 (Yellow wire), between the TCM and Splice Pack 205. Specifically inspect connector C106, a five terminal connector located below the left side underhood bussed electrical center, directly beneath the red battery cable terminal connection. Perform a mating terminal pull test on all of the terminals in this connector. Repair as required. 4. Observe the Gear Selected screen on the scan tool. The following values should be shown on the Tech 2(R) display and the vehicle's instrument panel cluster (if equipped with the I/P display). ^ "8" (shifter should be in the Park position) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 1739 ^ "7" (shifter should be in the Reverse position) ^ "5" (shifter should be in the Drive position) ^ "3" (shifter should be in the Third gear position) ^ "2" (shifter should be in the Second gear position) ^ "1" (shifter should be in the First gear position) ^ "0" (shifter should be in the Neutral Position) If the Gear Selected display does not match the shifter position in the vehicle, diagnose using one of the following methods. ^ Obtain a new PNP switch kit, P/N 29540479, from the Parts Department. ^ 0.1. Disconnect the wiring connector from the original transmission mounted PNP switch. ^ 0.2. Connect the new switch to the wiring connector. ^ 0.3. Return to Step # 4 above and observe the display as you rotate the switch. If all positions indicate properly, refer to the Correction section below. ^ Use the DTC P0708 diagnostic chart in Service Information (SI) under Transmission/Transaxle/Automatic Transmission - Allison. Reference SI Document ID # 769549 for the wiring schematic for this symptom. The PNP switch, as referenced in SI, is known as the NSBU switch in the Parts information. It is now serviced with a Park Neutral Position Switch Kit, P/N 29540479. Flashing PRNDL Display A flashing PRNDL display may be the result of incorrect sensor inputs or transmission abuse protection modes being received by the TCM. The following are some of these conditions: ^ The transfer case is/was in Neutral. ^ The transfer case is/was shifted into Neutral when the vehicle is moving. ^ A decrease of the input turbine speed was not detected when the gear selector was moved into any gear. ^ A low transmission fluid level. ^ A misadjusted PNP/NSBU switch. ^ Turbine input speed or output speed sensor failure. ^ Failures of the shift solenoids to route the transmission oil to the proper clutch assemblies within the transmission. ^ Failures of the transmission clutch packs (C1 or C5 for first gear, C3 or C5 for Reverse). ^ Failure to detect proper line pressures when a gear range is selected, which may be the result of normal maintenance such as a transmission fluid change having been completed, or the transmission pan was removed for a filter replacement or other type service. Transmission abuse protection modes are encountered when a customer performs one of the following types of maneuvers: ^ Shifting from Neutral to Drive/Reverse when the engine RPM is greater than 1400 RPM. ^ Shifting from Drive to Reverse when the throttle position (TPS) is greater than 25%, such as rocking the vehicle when stuck in an attempt to free the vehicle. ^ When the transmission output speed is greater than 300 RPM from attempted changes in direction such as Reverse to Drive, Drive to Reverse or Neutral to Reverse shifts. When the TCM encounters any one of the above conditions, the TCM will flash the PRNDL and default the transmission to Neutral. A flashing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 1740 PRNDL indicates something is/was incorrect. The transmission may need the attention of a qualified service technician. Correction 1. Disconnect the wiring harness from the PNP switch. 2. Disconnect the shift linkage/cable from the shift lever at the transmission. 3. With a wrench keeping the shift lever from rotating, remove the nut from the end of the selector shaft. 4. Use a file to remove any burrs or raised metal where the selector lever was seated against the shoulder of the selector shaft. Important: If the old PNP switch will not slide from the selector shaft without the effort, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 5. Remove the two bolts that attach the PNP switch and remove the switch by sliding it outward over the selector shaft. 6. Make sure the selector shaft is in the N (neutral) position (using a wrench on the selector shaft flats, rotate the shaft to its furthest clockwise position and then rotate counterclockwise two detents). Important: If the new PNP switch will not slide onto the selector shaft easily, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 7. Slide the new PNP switch over the selector shaft with the neutral assurance bracket 920 facing outward and maintaining the correct PNP switch orientation to the selector shaft. Install and hand tighten the two PNP switch attaching bolts so that the PNP switch and bracket may be rotated within the adjusting slots with some effort. 8. While holding the neutral assurance bracket in engagement with the PNP switch, tighten the two bolts that attach the PNP switch to the transmission case. Tighten Tighten the bolts to 27 N.m (20 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 1741 9. Remove and discard the neutral assurance bracket. Important: Installation of the front shield and rear shields are important. Without proper installation of the shield, a return repair is probable. Follow all directions as listed on the installation instructions sheet included in the Switch kit, P/N 29540479. 10. Fit the new shield onto the PNP switch so that it fits securely against the switch. Make sure this is done before reinstalling the shift lever. 11. Reinstall the shift lever. With a wrench keeping the shift lever from rotating, install the nut on the end of the selector shaft. Tighten. Tighten the nut to 24 N.m (18 lb ft). 12. Connect the wiring harness connectors to the PNP switch. 13. Attach the selector cable to the lever. Check and adjust if needed. 14. Go back to step 4 of the Diagnostics and insure the Tech 2 readings match the shift lever positions. Important: Clear all DTCs before returning the vehicle to the customer. 15. Return the vehicle to the customer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 1742 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation Power Seat Control Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 1748 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 1754 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 1755 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 1756 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 1759 Transmission Position Switch/Sensor: Adjustments Automatic Transmission - Allison Park/Neutral Position Switch Adjustment ^ Tools Required J 41364-A PNP Switch Adjusting Tool Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Make sure the selector shaft is in the N (Neutral) position as follows: ^ Place a wrench on the selector shaft flats and rotate the shaft to its furthest clockwise position. ^ Rotate the selector shaft counter-clockwise two detents. 2. Be sure that J 41364-A (2) is in the proper position on PNP switch (1). 3. While maintaining the correct PNP switch-to-selector-shaft alignment, slide the new PNP switch (5) over the selector shaft (4). 4. Notice: Refer to Component Fastener Tightening Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 1760 While holding J 41364-A in engagement with the PNP switch, install the two bolts (6) so that the PNP switch may be rotated with some effort. ^ Tighten the two bolts (6) to 27 Nm (20 ft. lbs.). 5. Remove J 41364-A. 6. Install splash shield (1), concave side toward PNP switch (3), over selector shaft (2). 7. Notice: Refer to Transmission Selector Shaft Abuse Notice in Service Precautions. Reinstall Shift Lever (2). Install nut (3), by hand, on the end of selector shaft (4). Use a wrench (1) to keep the shift lever from rotating. ^ Tighten nut (3) to 24 Nm (18 ft. lbs.) 8. Reconnect the shift selector linkage/cable to the shift lever (2). 9. Connect the external wiring harness to the PNP switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L80-E/4L85-E Park/Neutral Position Switch Replacement Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 1763 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 1764 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 1765 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Park Lock Pawl and Actuator Replacement Park Lock Pawl and Actuator Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the park/neutral position (PNP) switch. 3. Remove the manual shaft nut and pin. 4. Remove the detent lever and actuator. 5. Remove the parking pawl bracket bolts. 6. Remove the parking pawl return spring. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 1766 7. Use the modified screw extractor in order to remove the plug. 8. Remove the parking pawl shaft retainer, shaft and pawl. 9. Important: If the manual shaft binds in the case during removal, file or sand the shaft in the area adjacent to the detent lever. Remove the manual shaft. 10. Remove the manual shaft seal. Installation Procedure 1. Install the pawl shaft. 2. Install the parking pawl. 3. Install the plug using a 8 mm or (5/16 inch) rod with Loctite® or equivalent. 4. Install the retainer. 5. Install the pawl return spring. 6. Install the detent lever to the actuator. 7. Install the actuator over the parking pawl. 8. Install the manual shaft seal. 9. Lubricate the manual shaft with transmission oil and install the manual shaft into the case. 10. Install the nut on the shaft. 11. Install the roll pin. 12. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 1767 Install the parking lock bracket bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 13. Install the PNP switch. 14. Install the transmission filter. 15. Fill the transmission to the proper level with Dexron® III transmission fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 1768 Transmission Position Switch/Sensor: Service and Repair Automatic Transmission - Allison Park/Neutral Position Switch Replacement PNP Switch Removal Refer to Park/Neutral Position Switch Removal. PNP Switch Install Refer to Park/Neutral Position Switch Installation. 7. Notice: Refer to Transmission Selector Shaft Abuse Notice in Service Precautions. Reinstall shift lever (2). Install nut (3), by hand, on the end of selector shaft (4). Use a wrench (1) to keep the shift lever from rotating. ^ Tighten nut (3) to 24 Nm (18 ft. lbs.). 8. Reconnect the shift selector linkage/cable to the shift lever (2). 9. Connect the external wiring harness to the PNP switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Electrical Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Electrical Specifications > Page 1773 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 1774 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Automatic Transmission 4L80-E/4L85-E Transmission Speed Sensor: Diagrams Automatic Transmission - 4L80-E/4L85-E Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Automatic Transmission 4L80-E/4L85-E > Page 1777 Transmission Speed Sensor: Diagrams Automatic Transmission - Allison Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Automatic Transmission 4L80-E/4L85-E > Page 1778 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E Transmission Speed Sensor: Service and Repair Automatic Transmission - 4L80-E/4L85-E Input Shaft Speed Sensor Replacement Input Shaft Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1). 5. Inspect the input speed sensor (1) for any evidence of damage. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 1781 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the input speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector (1). 5. Lower the vehicle. Output Shaft Speed Sensor Replacement Output Shaft Speed Sensor Replacement Removal Procedure Important: This procedure is for 2-wheel drive (2WD) vehicles only. If the vehicle is equipped with 4-wheel drive (4WD), the output speed sensor is located on the transfer case. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 1782 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2). 5. Inspect the output speed sensor (2) for any evidence of damage. Installation Procedure 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the output speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 1783 4. Connect the output speed sensor (2) electrical connector. 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 1784 Transmission Speed Sensor: Service and Repair Automatic Transmission - Allison Speed Sensor Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Be sure the vehicle ignition is turned off. 2. Disconnect the external wiring harness from the speed sensor. 3. Remove the bolt (1) from the speed sensor and carefully remove the speed sensor (2). Installation Procedure 1. Important: Do not rotate the sensor in its retaining bracket. Changing the sensor/bracket orientation may cause improper operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 1785 Install a new a O-ring (3) on the speed sensor (2). Lubricate the O-ring with clean transmission fluid. 2. Install the new speed sensor (2) into the speed sensor bore. Align the hole in the retaining bracket with the bolt hole in the speed sensor boss. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor bolt (1). ^ Tighten bolt (1) to 12 Nm (108 inch lbs.). 4. Reconnect the external wiring harness to the speed sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Electrical Specifications Transmission Temperature Sensor/Switch: Electrical Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Electrical Specifications > Page 1790 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Electrical Specifications > Page 1791 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Component Locations Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Component Locations > Page 1794 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Instrument Panel Switches-LH Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 1799 Four Wheel Drive Selector Switch: Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 1800 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Transfer Case - NVG 246-NP8 Four Wheel Drive Selector Switch: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (I/P) cluster bezel. 2. Using a flat-tipped screwdriver, gently pry the retaining clips open on the housing. 3. Slide out the selector switch until the electrical connector are accessible. 4. Disconnect the selector switch electrical connectors (2, 3). 5. Remove the selector switch from the housing. Installation Procedure 1. Position the selector switch close to the housing so the electrical connectors can be connected. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Transfer Case - NVG 246-NP8 > Page 1803 2. Connect the selector switch electrical connectors (2, 3). 3. Slide the selector switch into the housing until the switch snaps into place. Important: Make sure that the selector switch is seated properly in the housing before installing the I/P cluster bezel. 4. Install the I/P cluster bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Transfer Case - NVG 246-NP8 > Page 1804 Four Wheel Drive Selector Switch: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (IP) cluster bezel. 2. Pull the tabs on the side of the transfer case driver control switch out. 3. Pull the transfer case driver control switch straight out from the panel. Installation Procedure 1. Important: Make sure that the transfer case control switch is seated properly in the instrument panel before installing the instrument panel trim bezel. Install the transfer case driver control switch into the instrument panel. 2. Install the IP cluster bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair Gear Sensor/Switch: Service and Repair Encoder Motor Sensor Replacement Removal Procedure Important: For ease of reassembly, shift the transfer case to 2HI prior to removing any components. 1. Remove the encoder motor. 2. Place the encoder motor on a clean work bench, 3. Remove the 2 screws (2) from the motor cover. 4. Remove the 2 screws (1) from the casting. 5. Remove the cover. 6. Remove and save the shim on the output gear. 7. Remove and discard the orange rubber seal from the cover. 8. Remove the output gear (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Page 1808 9. Disassemble the harness connector (1) from the encoder. 10. Remove the encoder from the output shaft using a flat tip screwdriver. Installation Procedure 1. Assemble the harness to the NEW encoder with the connector legend "TOP" (1) and the encoder part number facing up. 2. Assemble the output shaft into the encoder, being sure to align the encoder tab with the groove on the shaft. 3. Ensure the encoder is seating properly on the output gear. 4. Place the output shaft encoder on the casting. 5. Place the grommet harness on the casting slot, the flat area on the grommet will be facing up. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Page 1809 6. With the output gear encoder assembly in hand, carefully align the casting and output gear timing marks (1). 7. At the same time, be sure to align the encoder phasing post (1) with the phasing slot (2) in the casting and insert the shaft into the bushing. 8. Verify that the output gear and idler are engaged properly. 9. Seat the harness wires on the casting channel. 10. Place the shim on the output shaft gear. 11. Press a NEW seal into the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Page 1810 12. Install the cover. Notice: Refer to Fastener Notice in Service Precautions. 13. Install 2 NEW screws (1) to the casting. ^ Tighten the screws to 2 Nm (18 inch lbs.). 14. Install 2 NEW longer screws (2) to the motor cover. ^ Tighten the screws to 3 Nm (26 inch lbs.). 15. Install the encoder motor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: All Technical Service Bulletins Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set > Page 1819 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 06-04-21-001 > May > 06 > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: Customer Interest Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set > Page 1829 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 06-04-21-001 > May > 06 > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front > Page 1837 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 Speed Sensor: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 1840 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 1841 Speed Sensor: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Speed Sensor Replacement - Front Transfer Case Speed Sensor Replacement - Front Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the front speed sensor electrical connector (5). 3. Remove the front speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the front speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 1842 2. Connect the front speed sensor electrical connector (5). 3. Install the transfer case shield, if equipped. Transfer Case Speed Sensor Replacement - Left Rear Transfer Case Speed Sensor Replacement - Left Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the left rear speed sensor electrical connector (4). 3. Remove the left rear speed sensor. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 1843 1. Notice: Refer to Fastener Notice in Service Precautions. Install the left rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the left rear speed sensor electrical connector (4) 3. Lower the vehicle. Transfer Case Speed Sensor Replacement - Right Rear Transfer Case Speed Sensor Replacement - Right Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the right rear speed sensor electrical connector (3). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 1844 3. Remove the right rear speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the right rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the right rear speed sensor electrical connector (3). 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 1845 Speed Sensor: Service and Repair Transfer Case - NVG 261-NP2 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 1846 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 1847 Speed Sensor: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector. 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 1848 2. Connect the speed sensor electrical connector. 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1854 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1855 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1856 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1857 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1858 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1859 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1860 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1861 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1862 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1863 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1864 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1865 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1866 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1867 Power Window Switch: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1868 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1869 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1870 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1871 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1872 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1873 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1874 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1875 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1876 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1877 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1878 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1879 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1880 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1881 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1882 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1883 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1884 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1885 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1886 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1887 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1888 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1889 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1890 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1891 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1892 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1893 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1894 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1895 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1896 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1897 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1898 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1899 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1900 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1901 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1902 Power Window Switch: Connector Views Window Switch - LR (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1903 Window Switch - RR (Crew Cab Only) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1904 Window Switch - RR (Crew Cab Only) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Rear Door Power Window Switch: Service and Repair Power Window Switch Replacement - Rear Door POWER WINDOW SWITCH REPLACEMENT - REAR DOOR REMOVAL PROCEDURE 1. Use a small flat-bladed tool in order to carefully pry the door power window switch from the door trim panel. 2. Disconnect the electrical connector from the switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the switch. 2. Install the switch to the door trim panel by pressing the switch into place until fully seated. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Rear Door > Page 1907 Power Window Switch: Service and Repair Switch Replacement - Door Lock and Side Window Driver SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - DRIVER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Rear Door > Page 1908 INSTALLATION PROCEDURE 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Rear Door > Page 1909 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Rear Door > Page 1910 Power Window Switch: Service and Repair Switch Replacement - Door Lock and Side Window Passenger SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - PASSENGER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Rear Door > Page 1911 INSTALLATION PROCEDURE 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Windshield Washer Reservoir Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1916 Washer Fluid Level Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1917 Washer Fluid Level Switch: Service and Repair WASHER SOLVENT CONTAINER LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the washer solvent container. 2. Using a small flat-bladed tool, remove the washer solvent container level sensor (1) and seal (2) from the container. INSTALLATION PROCEDURE 1. Position the washer solvent container level sensor (1) and the seal (2) to the container by pressing in until fully seated. 2. Install the washer solvent container. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1923 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1924 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1925 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1926 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1927 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1928 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1929 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1930 Alignment: Technical Service Bulletins Steering/Suspension - Revised Caster/Camber Adjustment Info - Revised Front Caster and Camber Adjustment Procedure # 02-03-07-002A - (Mar 24, 2005) Models: 1999-2000 Cadillac Escalade 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Express, Silverado, Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999 GMC Suburban 1999-2005 GMC Savana, Sierra, Yukon, Yukon XL, Yukon XL Denali This bulletin is being revised to add model years and clarify the information. Please discard Corporate Bulletin Number 02-03-07-002 (Section 03 - Suspension). When performing a wheel alignment on any of the above vehicles, please refer to the Front Caster and Camber Adjustment Procedure in SI before contacting the GM Technical Assistance Center (TAC) with issues concerning adjustments, caster out-of-spec, etc. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Trim Height Specifications Alignment: Specifications Trim Height Specifications Trim Height Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Trim Height Specifications > Page 1933 Alignment: Specifications Wheel Alignment Specifications Wheel Alignment Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Trim Height Specifications > Page 1934 Alignment: Specifications Fastener Tightening Specifications Fastener Tightening Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1935 Alignment: Description and Operation Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1936 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Lead/Pull Description Definition: At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Lead/pull is usually caused by the following factors: ^ Tire construction ^ Wheel alignment ^ Unbalanced steering gear The way in which a tire is built may produce lead/pull. The rear tires will not cause lead. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1937 Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure Alignment: Service and Repair Trim Height Inspection Procedure Trim Height Inspection Procedure Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: 1. Make sure the vehicle is on a level surface, such as a alignment rack. 2. Remove the alignment rack floating pins. 3. Set the tire pressures to the pressure shown on the certification label. 4. Check the fuel level. Add additional weight if necessary to simulate a full tank. 5. Make sure the rear compartment is empty except for the spare tire. 6. Close the doors and hood. Z Height Measurement Important: K models only the Z height must be adjusted before the alignment. The Z height dimension measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use a adjusting arm in order to adjust the Z height dimension. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. 1. Important: All dimensions are measured vertical to the ground. Cross vehicle Z heights should be within 12 mm (0.47 inch) to be considered correct. Place hand on the front bumper and jounce the front of the vehicle. Make sure that there is at least 38 mm (1.5 inch) of movement while jouncing. 2. Allow the vehicle to settle into position. 3. Measure from the pivot bolt center line (2) down to the lower corner (5) of the steering knuckle (1) in order to obtain the Z height measurement (4). 4. Repeat the jouncing operation 2 more times for a total of 3 times. 5. Use the highest and the lowest measurements to calculate the average height. 6. The true Z height dimension number is the average of the highest and the lowest measurements. Refer to Trim Height Specifications. Z Height Adjustment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 1940 1. For vehicles equipped with a torsion bar suspension turn the bolt (1) that contacts the torsion arm clockwise to raise the and counterclockwise to lower the height adjustment. One revolution of the bolt (1) into the nut increases the Z height by approximately 6.0 mm (0.2 inch). 2. For vehicles without torsion bars, replace damaged or worn components as necessary. D Height Measurement Important: There are no specified trim heights specifications on leaf spring vehicles because it is not an adjustable feature. The height of the suspension will depend on the option content of the vehicle as well as the aftermarket equipment that is placed on the vehicle. The measurements are used for comparison only and should be within 15 mm with the vehicle at curb and no accessories. 1. With the vehicle on a flat surface, lift upward on the rear bumper 38 mm (1.5 inch). 2. Allow the vehicle to settle into position. 3. Important: Measure the metal to metal contact points of the rear axle to the frame on the inboard side of the leaf springs. Measure the D height by measuring the distance between the bumper bracket and the top of the rear axle tube. 4. Repeat the jouncing operation 2 more times for a total of 3 times. 5. Use the highest and lowest measurements to calculate the average height. 6. The true D height dimension number is the average of the highest and the lowest measurements. 7. If these measurements are out of specifications, inspect for the following conditions: ^ Sagging front suspension Refer to Front Coil Springs Replacement or Torsion Bar Replacement in Front Suspension. ^ Sagging rear leaf/coil springs Refer to Leaf Spring Replacement in Rear Suspension. ^ Worn rear suspension components, such as leaf spring bushings Refer to Spring Bushing Replacement in Rear Suspension. ^ Improper tire inflation Refer to Tire Inflation Pressure Specifications. ^ Improper weight distribution ^ Collision damage Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 1941 Alignment: Service and Repair Measuring Wheel Alignment (W/Rear Wheel Steering) Measuring Wheel Alignment (w/Rear Wheel Steering) Learn Wheel Alignment After replacement of the handwheel position sensor, rear wheel position sensor, or rear wheel steering control module it is necessary to perform the learn wheel alignment procedure. Alignment Procedure Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: at a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicles straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in Tires and Wheels in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: ^ Inspect the tires for the proper inflation and irregular tire wear. ^ Inspect the runout of the wheels and the tires. ^ Inspect the wheel bearings for backlash and excessive play. ^ Inspect the ball joints and tie rod ends for looseness or wear. ^ Inspect the control arms and stabilizer shaft for looseness or wear. ^ Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications in Power Steering System. ^ Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Struts or Shock Absorbers On-Vehicle Testing in Suspension General Diagnosis. ^ Inspect the vehicle trim height. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis. ^ Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. ^ Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. 4. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications then perform the learn alignment procedure. Learn Wheel Alignment Procedure 1. Turn ignition to ON position, with the engine ON. 2. Install the scan tool. 3. Center the steering wheel. 4. Lift the rear of the vehicle off the ground ensuring the rear wheels are centered. 5. Go to the Learn Alignment menu choice in the scan tool. Follow the prompts on the scan tool. Important: When prompted by the scan tool you must turn the steering wheel a full 90 degrees to the left and a full 90 degrees to the right and then to center and hold. If this step is not done properly then it is possible to cause a false DTC for the steering wheel position sensor. 6. Press the continue button. 7. Use the scan tool to clear all rear wheel steering DTCs. (W/O Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 1942 Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: at a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicles straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in Tires and Wheels in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: ^ Inspect the tires for the proper inflation and irregular tire wear. ^ Inspect the runout of the wheels and the tires. ^ Inspect the wheel bearings for backlash and excessive play. ^ Inspect the ball joints and tie rod ends for looseness or wear. ^ Inspect the control arms and stabilizer shaft for looseness or wear. ^ Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications in Power Steering System. ^ Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Struts or Shock Absorbers On-Vehicle Testing in Suspension General Diagnosis. ^ Inspect the vehicle trim height. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis. ^ Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. ^ Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. 4. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 1943 Alignment: Service and Repair Front Wheel Alignment Front Caster and Camber Adjustment Front Caster and Camber Adjustment 1. Important: Caster measurements or valves must be compensated for the measured frame angle. Caster is relative to frame, the caster values must be compensated for the measured frame angle by using a digital protractor or equivalent on a flat portion of the frame in front of the rear tire. 2. Frame angle is positive when higher in the rear. Measure both sides of the frame and take an average from those measurements. Then add the average frame angle to the caster reading when making adjustments. 3. Frame angle is negative when lower in the rear. Measure both sides of the frame and take an average from the measurements. Then subtract the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 1944 average frame angle from the caster reading when making adjustments. 4. The caster and camber adjustments are made by rotating the offset cam bolt and the cam in the slotted frame bracket in order to reposition the control arm. Important: Before adjusting the caster and camber angles, jounce the front bumper three times to allow the vehicle to return to normal height. Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension is indicated in Trim Heights. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis. For an accurate reading, do not push or pull on the tires during the alignment process. 5. Determine the caster angle (2). Be sure to compensate for frame angle where required. 6. Determine the positive camber (2) or negative camber (3) angle. 7. Remove the pinned adjusting cam insert. Do not reinstall the cam insert. 8. Loosen the upper control arm cam adjustment bolts. Notice: Refer to Fastener Notice in Service Precautions. 9. Adjust the caster and the camber angle by turning the cam bolts until the specifications have been met.When the adjustments are complete, hold the cam bolt head in order to ensure the cam bolt position does not change while tightening the nut. ^ Tighten the cam nuts to 190 Nm (140 ft. lbs.). 10. Verify that the caster and the camber are still within specifications. Refer to Wheel Alignment Specifications. When the caster and camber are within specifications, adjust the toe. Refer to Front Toe Adjustment. Front Toe Adjustment Front Toe Adjustment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 1945 1. Loosen the jam nut on the tie rod (2). 2. Rotate the inner tie rod (1) to the required toe specification setting. Refer to Wheel Alignment Specifications. 3. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the jam nut on the tie rod. ^ Tighten the tie rod jam to 68 Nm (50 ft. lbs.). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Rear Toe Adjustment Rear Toe Adjustment 1. Loosen the jam nut on the tie rod (1). 2. Rotate the inner tie rod to the required toe specification setting. Refer to Wheel Alignment Specifications. 3. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the jam nut on the tie rod. ^ Tighten the tie rod jam to 65 Nm (48 ft. lbs.). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations FUEL SCHRADER VALVE The Fuel Schrader Valve is located on the right front of the engine, on the right upper valve rocker Arm cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information Not Supplied By The Manufacturer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Air Cleaner Fresh Air Duct/Hose: Customer Interest Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 1963 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 1964 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 1965 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 1966 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 1967 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 1968 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 1969 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Air Cleaner Fresh Air Duct/Hose: All Technical Service Bulletins Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 1975 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 1976 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 1977 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 1978 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 1979 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 1980 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 1981 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Page 1982 Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR CLEANER OUTLET DUCT REPLACEMENT REMOVAL PROCEDURE 1. Loosen the outlet duct clamps at the turbocharger and the mass air flow (MAF)/intake air temperature (IAT) sensor. 2. Remove the air cleaner outlet duct. INSTALLATION PROCEDURE IMPORTANT: The air cleaner outlet duct must be fully seated against the positive stop feature on the turbocharger inlet. 1. Install the air cleaner outlet duct. NOTE: Refer to Fastener Notice in Service Precautions. 2. Tighten the outlet duct clamps at the turbocharger and the MAF/IAT sensor. Tighten Tighten the clamps to 6 N.m (53 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Restriction Indicator > Component Information > Description and Operation Air Cleaner Restriction Indicator: Description and Operation AIR CLEANER RESTRICTION INDICATOR The air cleaner restriction indicator is located on the air cleaner housing. If the area inside of the clear section is green, no air filter service is required. If the area inside the clear section is orange and Change Air Filter appears, replace the air filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Air Filter Element: Customer Interest Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 1994 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 1995 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 1996 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 1997 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 1998 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 1999 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2000 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2005 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Air Filter Element: All Technical Service Bulletins Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2011 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2012 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2013 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2014 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2015 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2016 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2017 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2022 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 05-00-90-001 > Jan > 05 > Diesel Engine - IMPORTANT Correct Air Filter Usage Air Filter Element: All Technical Service Bulletins Diesel Engine - IMPORTANT Correct Air Filter Usage Bulletin No.: 05-00-90-001 Date: January 05, 2005 INFORMATION Subject: Information on the Proper Air Filter for the Duramax(R) Diesel Models: 2001-2005 Chevrolet Silverado 2001-2005 GMC Sierra with 6.6L Duramax(R) Diesel Engine (VINs 1, 2 - RPOs LB7, LLY) The Duramax(R) air filter, P/N 25332443, is specific to the diesel engine due to the operating characteristics of a turbo charged diesel engine. The turbo allows for a much greater air volume rate than a normal aspirated engine. The Duramax(R) diesel air filter is reinforced to eliminate damage from the increased airflow of the turbo. The reinforcement is visually identified by the five ribs of epoxy that lies across the pleats of the clean side of the filter. If the correct air filter is not used, the filter may collapse or be torn in a Duramax(R) application. This damage will allow dust and dirt to be ingested into the turbo and engine causing serious damage. This damage is usually identified at the turbo vanes as well as extreme wear in the cylinder walls of the engine. There is evidence of gasoline engine air filters being used in the Duaramax(R) application. The 8.1 gas air filter, P/N 25313349, will fit into the air box of the Duramax(R) diesel; however, it does not have the required reinforcement of the diesel air filter. The 8.1 liter gas engine air filter should never be used in a Duramax(R) diesel engine. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 05-00-90-001 > Jan > 05 > Diesel Engine - IMPORTANT Correct Air Filter Usage Air Filter Element: All Technical Service Bulletins Diesel Engine - IMPORTANT Correct Air Filter Usage Bulletin No.: 05-00-90-001 Date: January 05, 2005 INFORMATION Subject: Information on the Proper Air Filter for the Duramax(R) Diesel Models: 2001-2005 Chevrolet Silverado 2001-2005 GMC Sierra with 6.6L Duramax(R) Diesel Engine (VINs 1, 2 - RPOs LB7, LLY) The Duramax(R) air filter, P/N 25332443, is specific to the diesel engine due to the operating characteristics of a turbo charged diesel engine. The turbo allows for a much greater air volume rate than a normal aspirated engine. The Duramax(R) diesel air filter is reinforced to eliminate damage from the increased airflow of the turbo. The reinforcement is visually identified by the five ribs of epoxy that lies across the pleats of the clean side of the filter. If the correct air filter is not used, the filter may collapse or be torn in a Duramax(R) application. This damage will allow dust and dirt to be ingested into the turbo and engine causing serious damage. This damage is usually identified at the turbo vanes as well as extreme wear in the cylinder walls of the engine. There is evidence of gasoline engine air filters being used in the Duaramax(R) application. The 8.1 gas air filter, P/N 25313349, will fit into the air box of the Duramax(R) diesel; however, it does not have the required reinforcement of the diesel air filter. The 8.1 liter gas engine air filter should never be used in a Duramax(R) diesel engine. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2032 Air Filter Element: Service Precautions NOTE: This information is contained within GM Bulletin 05-00-90-001 dated January 5, 2005. Subject: Information on the Proper Air Filter for the Duramax(R) Diesel Models: 2001-2005 Chevrolet Silverado and GMC Sierra with 6.6L Duramax(R) Diesel Engines (VINs 1, 2 - RPOs LB7, LLY) The Duramax(R) air filter. P/N 25332433, is specific to the diesel engine due to the operating characteristics of a turbocharged diesel engine. The turbo allows for a much greater air volume rate than a normally aspirated engine. The Duramax(R) diesel air filter is reinforced to eliminate damage from the increased airflow of the turbo. The reinforcement is visually identified by the five ribs of epoxy that lie across the pleats of the clean side of the filter. If the correct air filter is not used, the filter may collapse or be torn in a Duramax(R) application. This damage will allow dust and dirt to be ingested into the turbo and engine causing serious damage. This damage is usually identified at the turbo vanes as well as extreme wear in the cylinder walls of the engine. There is evidence of gasoline engine air filters being used in the Duramax(R) application. The 8.1 gas air filter, P/N 25313349 will fit into the air box of the Duramax(R) diesel; however, it does not have the required reinforcement of the diesel air filter. The 8.1 liter gas engine air filter should never be used in a Duramax(R) diesel engine. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2033 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector (1). 2. Loosen the screws holding the air cleaner housing halves together. 3. Separate the housing halves and remove the air filter element. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2034 1. Install the air filter element into the lower air cleaner housing. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the upper housing cover and tighten the screws. Tighten Tighten the screws to 4 N.m (35 lb in). 3. Connect the MAF/IAT sensor electrical connector (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Improved Fuel Filter Design Fuel Filter: Technical Service Bulletins Fuel System - Improved Fuel Filter Design INFORMATION Bulletin No.: 04-06-04-070B Date: March 02, 2009 Subject: Information on Improved Fuel Filter for 6.6L Duramax(TM) Diesel Engine Models: 2001-2009 Chevrolet Silverado 2003-2009 Chevrolet Kodiak 2006-2009 Chevrolet Express 2001-2009 GMC Sierra 2003-2009 GMC TopKick 2006-2009 GMC Sierra Equipped with 6.6L Duramax(TM) Diesel Engine (VINs 1, 2, D, 6 - RPOs LB7, LLY, LBZ, LMM) Supercede: This bulletin is being revised to provide additional information to the field on fuel filter applications for the Duramax diesel engine. Please discard Corporate Bulletin Number 04-06-04-070A (Section 06 - Engine/Propulsion System). Important: It is acceptable to use diesel fuel containing up to 5% biodiesel (B5). Higher concentration (i.e., greater than B5) biodiesel-containing fuels or the use of unmodified bio-oils blended into diesel fuel at any concentration is not recommended and could damage the fuel system and engine. Such damage would not be covered by your warranty. A revised fuel filter is released that will service all 2001-2009 Chevrolet and GMC C/K models and 2003-2009 Chevrolet and GMC C4500/5500 Series vehicles with the 6.6L Duramax(TM) Diesel. The new coalescer filter provides the following benefits / improvements over the existing dual pleat design: ^ 150-200% increase in service life, depending on contaminant type Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Improved Fuel Filter Design > Page 2039 ^ Improved fuel system protection with some premium diesel and B5 biodiesel blends ^ Equivalent coarse water droplet removal efficiency of previous design ^ Greatly improved removal of emulsified water - a major contributor to fuel system issues Proper fuel filter servicing and the use of clean diesel fuel that is free of water or contaminants are critical for the longevity of fuel system components of a modern direct injected diesel engine. Adherence to the fuel filter change interval will help to ensure that the Duramax fuel system will be protected from contaminants and that the engine will continue to operate as designed. Purchasing fuel from a high volume fuel retailer increases the chances that the fuel is fresh and of good quality. Parts Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Page 2040 Fuel Filter: Locations FUEL FILTER/HEATER ELEMENT HOUSING Fuel Filter/Heater Element Housing Water In Fuel Sensor The Fuel Filter/Heater Element Housing is located on the right engine rocker cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Page 2041 Fuel Filter: Description and Operation FUEL FILTER The fuel filter is located on the rocker cover. The paper filter element traps particles in the fuel that may damage the fuel injection system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly Fuel Filter: Service and Repair Fuel Filter Assembly FUEL FILTER ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Drain the fuel from the fuel filter. Refer to Water-in-Fuel Draining Procedure. 2. Reposition the fuel hose clamps. 3. Remove the fuel hoses. 4. Disconnect the fuel filter electrical connectors. 5. Remove the fuel filter bracket bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 2044 6. Remove the fuel filter assembly. 7. Remove the fuel filter bracket bolts and bracket from the fuel filter/heater element housing. 8. Remove the fuel filter from the fuel filter/heater element housing. 9. Inspect the fuel filter, replace if necessary. INSTALLATION PROCEDURE 1. Install the fuel filter to the fuel filter/heater element housing. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel filter bracket and bolts to the fuel filter/heater element housing. Tighten Tighten the bolts to 20 N.m (15 lb ft). 3. Install the fuel filter assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 2045 4. Install the fuel filter bracket bolts. Tighten Tighten the bolts to 20 N.m (15 lb ft). 5. Connect the fuel filter electrical connectors. 6. Install the fuel hoses. 7. Position the fuel hose clamps. 8. Prime the fuel system. Refer to Fuel System Priming. 9. Start the engine. If the engine stalls, repeat the above step. 10. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 2046 Fuel Filter: Service and Repair Fuel Filter Element FUEL FILTER REPLACEMENT REMOVAL PROCEDURE 1. Drain the fuel from the fuel filter. Refer to Water-in-Fuel Draining Procedure. 2. Reposition the fuel hose clamps. 3. Remove the fuel hoses. 4. Disconnect the fuel filter connectors. 5. Unscrew the fuel filter from the fuel filter adapter. 6. Remove the water-in-fuel sensor from the fuel filter. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 2047 1. Install the water-in-fuel sensor to the NEW fuel filter. IMPORTANT: Inspect the fuel heater element housing for contamination. Contamination on the fuel heater element housing may cause leakage at the fuel filter. Coat the fuel filter seal with clean engine oil. 2. Screw on the NEW fuel filter to the fuel filter adapter. 3. Connect the fuel filter connectors. 4. Install the fuel hoses. 5. Position the fuel hose clamps. 6. Prime the fuel system. Refer to Fuel System Priming. 7. Start the engine. If the engine stalls, repeat the above step. 8. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 2048 Fuel Filter: Service and Repair Fuel Filter Life Reset FUEL FILTER LIFE RESET This message will appear when a reset is performed either by using the steering wheel controls or the following manual procedure. For vehicles with steering wheel controls: 1. Reset the fuel filter monitor. 2. Press and hold the select button for five seconds while the "FUEL FILTER LIFE" message is displayed. This message will appear on the DIC for ten seconds. For vehicles without steering wheel controls, do the following: 1. Without pressing the pedals, turn the ignition key to the "ON" position without starting the engine. 2. Wait five seconds. 3. Completely press the brake and the accelerator pedals simultaneously and hold for ten seconds. The system is now reset. 4. Turn the ignition key off. The next time the engine is started, the message will no longer be displayed. Always reset the FUEL FILTER LIFE system after a fuel filter change. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 2049 Fuel Filter: Service and Repair Fuel System Priming FUEL SYSTEM PRIMING IMPORTANT: In order for the DURAMAX diesel engine fuel system to work properly, the fuel lines must be full of fuel and contain no air. If air gets into the fuel lines, it will be necessary to prime the fuel system to eliminate the air before operating the vehicle. Air could have entered to system in one of the following ways: - The vehicle ran out of fuel. - The filter was removed for service or replacement. - The fuel lines were removed or disconnected for servicing. - The fuel filter water drain cock was opened while the engine was running. If one or more of the above occurred, air has entered the fuel system and you will need to prime the system prior to operating the vehicle. 1. Prior to priming the engine, ensure that the following is complete: - There is fuel in the fuel tank. - The fuel filter has been installed and properly tightened. - The fuel lines are properly connected. - The fuel filter is cool to the touch. - Any dirt or debris is removed from the fuel filter head and vent valve. 2. Open the vent valve by turning the screw counterclockwise several full turns. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 2050 3. Operate the priming pump until a small amount of fuel seeps from the vent valve. allow the pump to return upwards between pumps. When fuel is present, the filter is full of fuel and the system should be primed. 4. Close the vent valve. 5. Clean any fuel which accumulated on the fuel filter. 6. Start the engine and allow it to idle for a few minutes. 7. Check the filter for leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications GThe minimum compression in any one cylinder is 2069 kPa (300 psi). There should not be more than 345 kPa (50 psi) difference between a suspect cylinder and the average compression of all 8 cylinders. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2054 Compression Check: Testing and Inspection Engine Compression Test ^ Tools Required J 26999 Compression Gage - J 26999-20 Compression Gage Adapter - J 43244 Relay Puller Pliers 1. Ensure that the vehicle's batteries are in good condition, and fully charged. 2. Operate the vehicle until the engine is at normal operating temperature. 3. Shut off engine. 4. Disable fuel delivery system, by removing the IGN B relay with J 43244. 5. Disconnect glow plug nut; remove all 8 glow plugs. All 8 glow plugs must be removed from the engine during each cylinder test to obtain valid test results. 6. Prior to taking a compression reading, verify the cranking speed is greater than 140 RPM. If the cranking speed is below 140 RPM, repair the slow cranking speed condition before continuing with the compression test. Refer to Engine Cranks Slowly in Engine Electrical. 7. Install the J 26999-20 in the glow plug hole for the cylinder that is being checked. 8. Notice: Do not add oil to any cylinder during a compression test as extensive engine damage may result. Connect the J 26999 to the J 26999-20. 9. Using the vehicle's starter motor, rotate or crank the engine for 6 compression strokes, puffs, for the cylinder being tested. 10. Observe the J 26999 and note the reading as the compression test is being performed. A normal cylinder reading will be indicated if compression builds up quickly and evenly to the specified level. An abnormal reading will be indicated if compression is low on the first compression stroke, starts increasing on the following compression strokes but does not reach the specified level. 11. Record the compression reading for the cylinder just tested. 12. Disconnect the J 26999 from the J 26999-20 and remove adapter from the glow plug hole. 13. Repeat steps 8 through 13 for all remaining cylinders. All 8 cylinders must be tested to obtain valid test results. Record the readings. 14. The minimum compression in any one cylinder is 2069 kPa (300 psi). There should not be more than 345 kPa (50 psi) difference between a suspect cylinder and the average compression of all 8 cylinders. ^ Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. ^ Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes but does not reach normal. ^ Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Lash ........................................................................................................................................... .................................................. 0.3 mm (0.012 inch) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2058 Valve Clearance: Adjustments Valve Clearance Adjustment 1. Remove the fan clutch. 2. Remove the upper valve rocker arm covers. 3. Rotate the crankshaft in order to bring the number 1 cylinder to Top Dead Center (TDC) of the compression stroke. The number 1 cylinder is the front cylinder on the right bank. The mark on the crankshaft balancer should be aligned with the mark on the engine. 4. Loosen the valve adjusting screws. 5. Insert a feeler gauge between the tip of the rocker arm and the valve bridge. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2059 6. Adjust the valve lash to 0.3 mm (0.012 inch). Refer to Valve Clearance Adjustment Specifications to determine which valves can be adjusted when the engine is at TDC. Notice: Refer to Fastener Notice in Service Precautions. 7. Tighten the lock nut. Tighten nut to 22 Nm (16 ft. lbs.). 8. Rotate the crankshaft one revolution in order to bring the number 1 cylinder to TDC of the exhaust stroke. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2060 9. Loosen the valve adjusting screws. 10. Insert a feeler gage between the tip of the rocker arm and the valve bridge. 11. Adjust the valve clearance to 0.3 mm (0.0112 inch). Refer to Valve Clearance Adjustment Specifications to determine which valves can be adjusted when the engine is at TDC. 12. Tighten the lock nut. Tighten nut to 22 Nm (16 ft. lbs.). 13. Install the upper valve rocker arm covers. 14. Install the fan clutch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle Drive Belt: Customer Interest Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle TECHNICAL Bulletin No.: 05-06-01-018B Date: February 09, 2011 Subject: Accessory Drive Belt Chirp, Squeal or Squeak Type Noise at Cold Idle (Replace A/C Compressor/Power Steering Pump Mounting Bracket or Enlarge Bracket Bolt Holes) Models: 2004-2010 Chevrolet Silverado 2006-2010 Chevrolet Express 2004-2010 GMC Sierra 2006-2010 GMC Savana Equipped with 6.6L Duramax(R) Diesel Engine (VINs D, 2 - RPOs LBZ, LLY, LMM) Supercede: This bulletin is being revised to add model years and RPOs. Please discard Corporate Bulletin Number 05-06-01-018A (Section 06 - Engine/Propulsion System). Condition Important It should be noted that a chirp type noise on engine shutdown is normal for a diesel engine due to higher engine compression and the rapid stopping of the crankshaft. No repairs should be attempted for this condition. Some customers may comment on an accessory drive belt chirp, squeal, or squeak type noise at idle, especially on a cold start. The noise may be reduced or go away after the engine warms up. Cause Some 2004/2005 Silverado or Sierra trucks, with a 6.6L LLY engine produced before June, 2004, may have an A/C compressor/power steering pump mounting bracket and power steering rear mounting bracket that are machined slightly out of specification, causing a misaligned power steering pump. If the power steering pump is misaligned, it will force the accessory drive belt to run farther inboard on the fan pulley. When the belt leaves the fan pulley, the belt will not align properly to the crankshaft pulley grooves and create a chirp or squeak type noise at the point of interference. Vehicles built after June 2004 will already have the new A/C compressor/power steering pump mounting bracket installed, but still may exhibit belt noise caused by the power steering pump rear mounting bracket. Correction Vehicles built prior to June 2004, replace the A/C compressor/power steering pump mounting bracket. Vehicles built after June 2004, enlarge the rear power steering pump bracket bolt holes. 1. Follow the published service information (SI) diagnostics for drive belt chirping. The diagnostic chart for the drive belt chirping will ask to inspect for a misaligned accessory drive pulley. Important Remove the top section of the radiator shroud and TCM/cover to gain access to check alignment and measure the power steering pulley on the power steering pump shaft. 2. Verify that the power steering pulley is properly pressed onto the power steering pump shaft. Refer to SI for the power steering pulley replacement. If the pulley needs to be realigned on the power steering pump shaft, follow the published SI procedures for the power steering pulley replacement. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 2069 3. If the noise was not fully eliminated by the procedure in step 2, the power steering pulley may be adjusted with an allowable maximum variance of 1.0 mm (0.039 in) to the front from the flush position on the shaft to assist in eliminating any remaining belt noise. Refer to graphic illustration number 1 and number 2. Ensure that the power steering pump pulley illustration number 1 is flush against the power steering pump shaft illustration number 2, with an allowable variance of 1.0 mm (0.039 in). 4. If the noise was not fully eliminated by the procedure in step 3, and there are no other concerns found, follow the published SI diagnostics for drive belt chirping. Then, if the vehicle was built prior to June 2004 go to step 5. If the vehicle was built after June 2004, go to step 6. 5. Vehicles Built Prior to June 2004: 1. Replace the A/C compressor/power steering pump mounting bracket with P/N 97362175. Refer to graphic illustration number 1. Follow the published SI procedures for the Air Conditioning (A/C) Compressor and Power Steering Pump Mounting Bracket Replacement. 2. With the new A/C compressor/power steering pump mounting bracket installed, reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2") drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear power steering bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 2070 6. Vehicles Built After June 2004: 1. Remove the front and rear power steering bracket bolts from the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. 2. Reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2 in) drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Dual Generator System New belts are not available for dual generator systems. If a belt chirp noise is occurring on a dual generator system, please complete a Field Product Report (FPR). The instructions for completing a FPR can be found in Service Bulletin Number 02-00-89-002G. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 2071 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Drive Belt: Customer Interest Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2076 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2077 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2078 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2079 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2080 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2081 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2082 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-01-003 > Mar > 07 > Diesel Engine - Chirp/Squeal On Cold Start Idle Drive Belt: Customer Interest Diesel Engine - Chirp/Squeal On Cold Start Idle Bulletin No.: 07-06-01-003 Date: March 07, 2007 TECHNICAL Subject: LBZ LB7 LLY 6.6L Duramax(R) Diesel Engine Accessory Drive Belt Chirp, Squeal, or Squeak Type Noise at Cold Start Idle (Replace Accessory Drive Belt) Models: 2002-2007 Chevrolet Silverado (Classic) 2006-2007 Chevrolet Express 2003-2007 Chevrolet Kodiak C4500/C5500 Series 2002-2007 GMC Sierra (Classic) 2006-2007 GMC Savana 2003-2007 GMC TopKick C4500/C5500 Series with 6.6L Duramax(R) Diesel Engine (VINs D, 1, 2 - RPOs LBZ, LB7, LLY) Attention: Do not replace the accessory drive belt for a chirp noise during engine shutdown. This is a normal condition for a diesel engine. Condition Some customers may comment on an accessory drive belt chirp, squeal, or squeak type noise at idle, especially on a cold start. The noise may be reduced or go away after the engine warms up. Correction Refer to Service Bulletin Number 05-06-01-018A. Follow the service procedures outlined in the bulletin to diagnose and repair an accessory drive belt chirp, squeal, or squeak type noise at cold idle. If the noise was not fully eliminated by the service procedures outlined in the bulletin in step 1, then replace the accessory drive belt with a second design belt that may be less prone to noise. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-01-003 > Mar > 07 > Diesel Engine - Chirp/Squeal On Cold Start Idle > Page 2087 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-01-003 > Mar > 07 > Diesel Engine - Chirp/Squeal On Cold Start Idle > Page 2088 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle Drive Belt: All Technical Service Bulletins Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle TECHNICAL Bulletin No.: 05-06-01-018B Date: February 09, 2011 Subject: Accessory Drive Belt Chirp, Squeal or Squeak Type Noise at Cold Idle (Replace A/C Compressor/Power Steering Pump Mounting Bracket or Enlarge Bracket Bolt Holes) Models: 2004-2010 Chevrolet Silverado 2006-2010 Chevrolet Express 2004-2010 GMC Sierra 2006-2010 GMC Savana Equipped with 6.6L Duramax(R) Diesel Engine (VINs D, 2 - RPOs LBZ, LLY, LMM) Supercede: This bulletin is being revised to add model years and RPOs. Please discard Corporate Bulletin Number 05-06-01-018A (Section 06 - Engine/Propulsion System). Condition Important It should be noted that a chirp type noise on engine shutdown is normal for a diesel engine due to higher engine compression and the rapid stopping of the crankshaft. No repairs should be attempted for this condition. Some customers may comment on an accessory drive belt chirp, squeal, or squeak type noise at idle, especially on a cold start. The noise may be reduced or go away after the engine warms up. Cause Some 2004/2005 Silverado or Sierra trucks, with a 6.6L LLY engine produced before June, 2004, may have an A/C compressor/power steering pump mounting bracket and power steering rear mounting bracket that are machined slightly out of specification, causing a misaligned power steering pump. If the power steering pump is misaligned, it will force the accessory drive belt to run farther inboard on the fan pulley. When the belt leaves the fan pulley, the belt will not align properly to the crankshaft pulley grooves and create a chirp or squeak type noise at the point of interference. Vehicles built after June 2004 will already have the new A/C compressor/power steering pump mounting bracket installed, but still may exhibit belt noise caused by the power steering pump rear mounting bracket. Correction Vehicles built prior to June 2004, replace the A/C compressor/power steering pump mounting bracket. Vehicles built after June 2004, enlarge the rear power steering pump bracket bolt holes. 1. Follow the published service information (SI) diagnostics for drive belt chirping. The diagnostic chart for the drive belt chirping will ask to inspect for a misaligned accessory drive pulley. Important Remove the top section of the radiator shroud and TCM/cover to gain access to check alignment and measure the power steering pulley on the power steering pump shaft. 2. Verify that the power steering pulley is properly pressed onto the power steering pump shaft. Refer to SI for the power steering pulley replacement. If the pulley needs to be realigned on the power steering pump shaft, follow the published SI procedures for the power steering pulley replacement. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 2094 3. If the noise was not fully eliminated by the procedure in step 2, the power steering pulley may be adjusted with an allowable maximum variance of 1.0 mm (0.039 in) to the front from the flush position on the shaft to assist in eliminating any remaining belt noise. Refer to graphic illustration number 1 and number 2. Ensure that the power steering pump pulley illustration number 1 is flush against the power steering pump shaft illustration number 2, with an allowable variance of 1.0 mm (0.039 in). 4. If the noise was not fully eliminated by the procedure in step 3, and there are no other concerns found, follow the published SI diagnostics for drive belt chirping. Then, if the vehicle was built prior to June 2004 go to step 5. If the vehicle was built after June 2004, go to step 6. 5. Vehicles Built Prior to June 2004: 1. Replace the A/C compressor/power steering pump mounting bracket with P/N 97362175. Refer to graphic illustration number 1. Follow the published SI procedures for the Air Conditioning (A/C) Compressor and Power Steering Pump Mounting Bracket Replacement. 2. With the new A/C compressor/power steering pump mounting bracket installed, reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2") drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear power steering bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 2095 6. Vehicles Built After June 2004: 1. Remove the front and rear power steering bracket bolts from the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. 2. Reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2 in) drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Dual Generator System New belts are not available for dual generator systems. If a belt chirp noise is occurring on a dual generator system, please complete a Field Product Report (FPR). The instructions for completing a FPR can be found in Service Bulletin Number 02-00-89-002G. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 2096 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics Drive Belt: All Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 2101 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 2102 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Drive Belt: All Technical Service Bulletins Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2107 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2108 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2109 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2110 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2111 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2112 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2113 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-06-01-003 > Mar > 07 > Diesel Engine - Chirp/Squeal On Cold Start Idle Drive Belt: All Technical Service Bulletins Diesel Engine - Chirp/Squeal On Cold Start Idle Bulletin No.: 07-06-01-003 Date: March 07, 2007 TECHNICAL Subject: LBZ LB7 LLY 6.6L Duramax(R) Diesel Engine Accessory Drive Belt Chirp, Squeal, or Squeak Type Noise at Cold Start Idle (Replace Accessory Drive Belt) Models: 2002-2007 Chevrolet Silverado (Classic) 2006-2007 Chevrolet Express 2003-2007 Chevrolet Kodiak C4500/C5500 Series 2002-2007 GMC Sierra (Classic) 2006-2007 GMC Savana 2003-2007 GMC TopKick C4500/C5500 Series with 6.6L Duramax(R) Diesel Engine (VINs D, 1, 2 - RPOs LBZ, LB7, LLY) Attention: Do not replace the accessory drive belt for a chirp noise during engine shutdown. This is a normal condition for a diesel engine. Condition Some customers may comment on an accessory drive belt chirp, squeal, or squeak type noise at idle, especially on a cold start. The noise may be reduced or go away after the engine warms up. Correction Refer to Service Bulletin Number 05-06-01-018A. Follow the service procedures outlined in the bulletin to diagnose and repair an accessory drive belt chirp, squeal, or squeak type noise at cold idle. If the noise was not fully eliminated by the service procedures outlined in the bulletin in step 1, then replace the accessory drive belt with a second design belt that may be less prone to noise. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-06-01-003 > Mar > 07 > Diesel Engine - Chirp/Squeal On Cold Start Idle > Page 2118 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-06-01-003 > Mar > 07 > Diesel Engine - Chirp/Squeal On Cold Start Idle > Page 2119 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 04-06-01-013 > Apr > 04 > Engine - Serpentine Drive Belt Wear Information Drive Belt: All Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics Drive Belt: All Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 2129 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 2130 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 04-06-01-013 > Apr > 04 > Engine - Serpentine Drive Belt Wear Information Drive Belt: All Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 2135 Drive Belt: Diagrams With RPO LLY With RPO LLY (Dual Generators) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 2136 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: ^ The drive belt ^ The drive belt tensioner ^ The drive belt idler pulley ^ The crankshaft balancer pulley ^ The accessory drive component mounting brackets ^ The accessory drive components ^ The power steering pump, if belt driven ^ The generator ^ The A/C compressor, if equipped ^ The engine cooling fan, if belt driven ^ The water pump, if belt driven ^ The vacuum pump, if equipped ^ The air compressor, if equipped The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. There also may be a V-belt style belt used to drive certain accessory drive components. The drive belts are made of different types of rubbers,chloroprene or EPDM, and have different layers or plys containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The chirping noise may be intermittent due to moisture on the drive belt or the accessory drive pulleys. In order to duplicate the customer's concern, it may be necessary to spray a small amount of water onto the drive belt. If spraying water onto the drive belt duplicates the symptom, cleaning the accessory belt pulleys may be the most probable solution. A loose or improper installation of a body or suspension component, or other item(s) on the vehicle may also cause the chirping noise. Test Description Steps 1 - 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2139 Steps 3(continued) - 15 The numbers below refer to the steps in the diagnostic table. 2. The chirping noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Remove the drive belt and operate the engine for a few seconds, this will verify if the chirping noise is related to the drive belt or not. With the drive belt removed the cooling fan will not operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt removed. 4. Inspect the drive belt for signs of pilling. Pilling is the small balls, pills or strings in the drive belt grooves caused by the accumulation of rubber dust. 6. Misalignment of the accessory drive pulleys may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 10. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 12. Inspection of the accessory drive pulleys should include inspecting for bends, dents, or other damage to the pulleys that would prevent the drive belt from seating properly in the pulley grooves, or on the smooth surface of the pulley when the back side of the drive belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2140 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt is usually caused by incorrect installation or the incorrect drive belt for the application. Minor misalignment of the accessory drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or fall off. Excessive misalignment of the accessory drive belt pulleys will cause excessive wear and may also make the drive belt fall off. Test Description Steps 1 - 6 The numbers below refer to the steps in the diagnostic table. 2. This inspection is to verify the drive belt is correctly installed on all of the accessory drive pulleys. Wear on the drive belt may be caused by mis-positioning the drive belt by one groove on a pulleys. 3. The installation of a drive belt that is too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on the pulleys. 4. This inspection is to verify the drive belt is not contacting any part of the engine or body while the engine is operating. There should be sufficient clearance when the accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2141 Drive Belt: Testing and Inspection Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the accessory drive belt pulleys, this may be caused by a pulley misalignment. An extra load that is quickly applied or released by an accessory drive component may cause the drive belt to fall off. Verify that the accessory drive components are operating properly. If the drive belt is the incorrect length, the drive belt tensioner may not maintain the proper tension on the drive belt. Test Description Step 1 - 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2142 Steps 3 - 12 The numbers below refer to the steps in the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. Inspect the drive belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the accessory drive pulleys may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure of that pulley. 5. Inspection of the accessory drive pulleys should include inspecting for bends, dents, or other damage to the pulleys that would prevent the drive belt from seating properly in the pulley grooves or on the smooth surface of a pulley when the back side of the drive belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will also cause the drive belt to fall off. 7. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. Missing, loose, or incorrect fasteners may cause pulley misalignment from the accessory drive brackets moving under load. Over tightening the fasteners may cause misalignment of the accessory component brackets. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2143 Drive Belt: Testing and Inspection Drive Belt Rumbling Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If, after replacing the drive belt and completing the diagnostic table, the rumbling is only heard with the drive belt installed, there might be an accessory drive component failure. Varying the load on the accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description Steps 1 - 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2144 The numbers below refer to the steps on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt is causing the rumbling. Rumbling may be confused with an internal engine noise due to the similarity in the description. Operate the engine for a few seconds, this will verify if the rumbling noise is related to the drive belt or not. With the drive belt removed the cooling fan will not operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt removed. 4. Inspect the drive belt to ensure that the drive belt is not the cause of the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating, this may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is a normal condition and acceptable. When the pilling is severe, the drive belt does not have a smooth surface for proper operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2145 Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The chirping noise may be intermittent due to moisture on the drive belt or the accessory drive pulleys. In order to duplicate the customer's concern, it may be necessary to spray a small amount of water onto the drive belt. If spraying water onto the drive belt duplicates the symptom, cleaning the accessory belt pulleys may be the most probable solution. A loose or improper installation of a body or suspension component, or other item(s) on the vehicle may also cause the chirping noise. Test Description Steps 1 - 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2146 Steps 3(continued) - 15 The numbers below refer to the steps in the diagnostic table. 2. The chirping noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Remove the drive belt and operate the engine for a few seconds, this will verify if the chirping noise is related to the drive belt or not. With the drive belt removed the cooling fan will not operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt removed. 4. Inspect the drive belt for signs of pilling. Pilling is the small balls, pills or strings in the drive belt grooves caused by the accumulation of rubber dust. 6. Misalignment of the accessory drive pulleys may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 10. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 12. Inspection of the accessory drive pulleys should include inspecting for bends, dents, or other damage to the pulleys that would prevent the drive belt from seating properly in the pulley grooves, or on the smooth surface of the pulley when the back side of the drive belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Drive Belt Excessive Wear Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2147 Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt is usually caused by incorrect installation or the incorrect drive belt for the application. Minor misalignment of the accessory drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or fall off. Excessive misalignment of the accessory drive belt pulleys will cause excessive wear and may also make the drive belt fall off. Test Description Steps 1 - 6 The numbers below refer to the steps in the diagnostic table. 2. This inspection is to verify the drive belt is correctly installed on all of the accessory drive pulleys. Wear on the drive belt may be caused by mis-positioning the drive belt by one groove on a pulleys. 3. The installation of a drive belt that is too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on the pulleys. 4. This inspection is to verify the drive belt is not contacting any part of the engine or body while the engine is operating. There should be sufficient clearance when the accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the accessory drive belt pulleys, this may be caused by a pulley misalignment. An extra load that is quickly applied or released by an accessory drive component may cause the drive belt to fall off. Verify that the accessory drive components are operating properly. If the drive belt is the incorrect length, the drive belt tensioner may not maintain the proper tension on the drive belt. Test Description Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2148 Step 1 - 2 Steps 3 - 12 The numbers below refer to the steps in the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. Inspect the drive belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the accessory drive pulleys may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure of that pulley. 5. Inspection of the accessory drive pulleys should include inspecting for bends, dents, or other damage to the pulleys that would prevent the drive belt from seating properly in the pulley grooves or on the smooth surface of a pulley when the back side of the drive belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will also cause the drive belt to fall off. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2149 7. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. Missing, loose, or incorrect fasteners may cause pulley misalignment from the accessory drive brackets moving under load. Over tightening the fasteners may cause misalignment of the accessory component brackets. Drive Belt Rumbling Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If, after replacing the drive belt and completing the diagnostic table, the rumbling is only heard with the drive belt installed, there might be an accessory drive component failure. Varying the load on the accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2150 Steps 1 - 8 The numbers below refer to the steps on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt is causing the rumbling. Rumbling may be confused with an internal engine noise due to the similarity in the description. Operate the engine for a few seconds, this will verify if the rumbling noise is related to the drive belt or not. With the drive belt removed the cooling fan will not operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt removed. 4. Inspect the drive belt to ensure that the drive belt is not the cause of the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating, this may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is a normal condition and acceptable. When the pilling is severe, the drive belt does not have a smooth surface for proper operation. Drive Belt Squeal Drive Belt Squeal Diagnosis Diagnostic Aids A loose or improper installation of a body or suspension component, or other items on the vehicle may cause the squeal noise. If the squeal is intermittent, verify that it is not the accessory drive components by varying their loads, making sure they are operating to their maximum capacity. An overcharged air conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing generator are suggested items to inspect. Test Description Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2151 Steps 1 - 5 Steps 5 (continued) - 9 The number(s) below refer to the steps in the diagnostic table. 2. The squeal may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise, do not proceed further with this table 3. The squeal may be an internal engine noise. Remove the drive belt and operate the engine for a few seconds, this will verify if the squealing noise is related to the drive belt or an accessory drive component. With the drive belt removed the cooling fan will not be operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt removed. 4. This test is to verify that an accessory drive components does not have a seized bearing. With the belt removed, test the bearings in the accessory drive components for smooth operation. Also test the accessory drive components with the engine operating by varying the load on the accessory drive components to verify that the components is operating properly. 5. This test is to verify that the drive belt tensioner is operating properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squealing noise. 6. This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from operating properly. Also if the incorrect Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2152 length drive belt was installed, it may not be routed correctly and may be turning an accessory drive component in the incorrect direction. 7. Misalignment of the accessory drive pulleys may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 8. Inspect the accessory drive pulleys to verify that they are the correct diameter or width. Using a known good vehicle, compare the accessory drive pulleys. Drive Belt Vibration Drive Belt Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. An overcharged Air Conditioning (A/C) system, a power steering system restriction, or the incorrect fluid, or an extra load placed on the generator are suggested items to inspect. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Test Description Steps 1 - 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2153 Steps 10 - 11 The numbers below refer to the steps in the diagnostic table. 2. This test is to verify that the vibration is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belt or accessory drive components may be causing the vibration. Remove the drive belt and operate the engine for a few seconds, this will verify if the vibration is related to the drive belt or not. With the drive belt removed the water pump will not operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt removed. 4. The drive belt may cause a vibration. While the drive belt is removed this is the best time to inspect the condition of the drive belt. 6. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smooth operation. Inspect for a bent fan shaft or bent mounting flange. 9. Inspect the water pump drive shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known good water pump. 10. Accessory drive component brackets that are bent, cracked, or loose may put an extra strain on that accessory drive component causing it to vibrate. Drive Belt Whine Drive Belt Whine Diagnosis Diagnostic Aids The drive belt will not cause the whine. If the whine is intermittent, verify that it is not the accessory drive components by varying their loads, making sure they are operating to their maximum capacity. An overcharged air conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing generator are suggested items to inspect. Test Description Steps 1 - 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2154 Steps 3 - 5 The numbers below refer to the steps in the diagnostic table. 3. This test is to verify that the whine is being caused by the accessory drive components. Remove the drive belt and operate the engine for a few seconds, this will verify if the whining noise is related to the accessory drive component. With the drive belt removed the cooling fan will not operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt removed. 4. The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the proper removal and replacement procedure. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 2155 Drive Belt: Service and Repair Drive Belt Replacement Removal Procedure 1. Install a 3/8 inch breaker bar into the tensioner opening and rotate the tensioner counterclockwise. 2. Remove the belt from the tensioner. 3. Slowly release the tension on the tensioner arm. 4. Remove the drive belt from the drive pulleys, if equipped with a single generator. 5. Remove the drive belt from the drive pulleys, if equipped with dual generators. 6. Remove the drive belt from the vehicle. 7. Inspect the drive belt for excessive cracking or any visible damage, replace if necessary. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 2156 1. Install the drive belt to the vehicle. 2. Route the drive belt over and/or around all the drive pulleys except for the tensioner, if equipped with dual generators. 3. Route the drive belt over and/or around all the drive pulleys except for the tensioner, if equipped with a single generator. 4. Install a 3/8 inch breaker bar into the tensioner opening and rotate the tensioner counterclockwise. 5. Install the belt to the tensioner. 6. Slowly release the tension on the tensioner arm. 7. Inspect the drive belt for proper installation on and/or around all pulleys. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Air Cleaner Fresh Air Duct/Hose: Customer Interest Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2167 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2168 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2169 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2170 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2171 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2172 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2173 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Air Cleaner Fresh Air Duct/Hose: All Technical Service Bulletins Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2179 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2180 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2181 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2182 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2183 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2184 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2185 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Page 2186 Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR CLEANER OUTLET DUCT REPLACEMENT REMOVAL PROCEDURE 1. Loosen the outlet duct clamps at the turbocharger and the mass air flow (MAF)/intake air temperature (IAT) sensor. 2. Remove the air cleaner outlet duct. INSTALLATION PROCEDURE IMPORTANT: The air cleaner outlet duct must be fully seated against the positive stop feature on the turbocharger inlet. 1. Install the air cleaner outlet duct. NOTE: Refer to Fastener Notice in Service Precautions. 2. Tighten the outlet duct clamps at the turbocharger and the MAF/IAT sensor. Tighten Tighten the clamps to 6 N.m (53 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Restriction Indicator > Component Information > Description and Operation Air Cleaner Restriction Indicator: Description and Operation AIR CLEANER RESTRICTION INDICATOR The air cleaner restriction indicator is located on the air cleaner housing. If the area inside of the clear section is green, no air filter service is required. If the area inside the clear section is orange and Change Air Filter appears, replace the air filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Air Filter Element: Customer Interest Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2198 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2199 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2200 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2201 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2202 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2203 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2204 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2209 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Air Filter Element: All Technical Service Bulletins Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2215 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2216 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2217 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2218 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2219 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2220 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2221 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON > Page 2226 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-00-90-001 > Jan > 05 > Diesel Engine - IMPORTANT Correct Air Filter Usage Air Filter Element: All Technical Service Bulletins Diesel Engine - IMPORTANT Correct Air Filter Usage Bulletin No.: 05-00-90-001 Date: January 05, 2005 INFORMATION Subject: Information on the Proper Air Filter for the Duramax(R) Diesel Models: 2001-2005 Chevrolet Silverado 2001-2005 GMC Sierra with 6.6L Duramax(R) Diesel Engine (VINs 1, 2 - RPOs LB7, LLY) The Duramax(R) air filter, P/N 25332443, is specific to the diesel engine due to the operating characteristics of a turbo charged diesel engine. The turbo allows for a much greater air volume rate than a normal aspirated engine. The Duramax(R) diesel air filter is reinforced to eliminate damage from the increased airflow of the turbo. The reinforcement is visually identified by the five ribs of epoxy that lies across the pleats of the clean side of the filter. If the correct air filter is not used, the filter may collapse or be torn in a Duramax(R) application. This damage will allow dust and dirt to be ingested into the turbo and engine causing serious damage. This damage is usually identified at the turbo vanes as well as extreme wear in the cylinder walls of the engine. There is evidence of gasoline engine air filters being used in the Duaramax(R) application. The 8.1 gas air filter, P/N 25313349, will fit into the air box of the Duramax(R) diesel; however, it does not have the required reinforcement of the diesel air filter. The 8.1 liter gas engine air filter should never be used in a Duramax(R) diesel engine. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 01-07-30-036H > Jan > 09 > A/T Control DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 2240 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 2250 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2251 Air Filter Element: Service Precautions NOTE: This information is contained within GM Bulletin 05-00-90-001 dated January 5, 2005. Subject: Information on the Proper Air Filter for the Duramax(R) Diesel Models: 2001-2005 Chevrolet Silverado and GMC Sierra with 6.6L Duramax(R) Diesel Engines (VINs 1, 2 - RPOs LB7, LLY) The Duramax(R) air filter. P/N 25332433, is specific to the diesel engine due to the operating characteristics of a turbocharged diesel engine. The turbo allows for a much greater air volume rate than a normally aspirated engine. The Duramax(R) diesel air filter is reinforced to eliminate damage from the increased airflow of the turbo. The reinforcement is visually identified by the five ribs of epoxy that lie across the pleats of the clean side of the filter. If the correct air filter is not used, the filter may collapse or be torn in a Duramax(R) application. This damage will allow dust and dirt to be ingested into the turbo and engine causing serious damage. This damage is usually identified at the turbo vanes as well as extreme wear in the cylinder walls of the engine. There is evidence of gasoline engine air filters being used in the Duramax(R) application. The 8.1 gas air filter, P/N 25313349 will fit into the air box of the Duramax(R) diesel; however, it does not have the required reinforcement of the diesel air filter. The 8.1 liter gas engine air filter should never be used in a Duramax(R) diesel engine. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2252 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector (1). 2. Loosen the screws holding the air cleaner housing halves together. 3. Separate the housing halves and remove the air filter element. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2253 1. Install the air filter element into the lower air cleaner housing. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the upper housing cover and tighten the screws. Tighten Tighten the screws to 4 N.m (35 lb in). 3. Connect the MAF/IAT sensor electrical connector (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Locations Cabin Air Filter: Locations This vehicle does not have a factory installed Cabin Air Filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Locations > Page 2257 Cabin Air Filter: Service and Repair This Article has been updated by bulletin #PIT3330, dated December 22, 2004. Condition/Concern: A customer may inquire about the availability of the passenger compartment air filter. Recommendation/Instructions: Starting in 2003 model year, the passenger compartment air filter is no longer available as a factory option. With the redesigned HVAC case, there is no longer a cavity for the filter. The GM parts catalog indicates there is a replacement filter available; however, there is no provision for it. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > A/T - Allison, Service Interval/Filter Change Correction Fluid Filter - A/T: Technical Service Bulletins A/T - Allison, Service Interval/Filter Change Correction Bulletin No.: 05-00-90-005 Date: May 26, 2005 SERVICE MANUAL UPDATE Subject: Revised Maintenance and Lubrication for Automatic Transmission Service Interval/Correct Filter to Replace Models: 2001-2006 Chevrolet Silverado 2001-2006 GMC Sierra with Allison(R) Automatic Transmission This bulletin is being issued to revise the first automatic transmission service interval and specify what filter to replace in the Maintenance and Lubrication sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI for 2001-2004. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The 2005 and 2006 Owner's Manuals have also been corrected. The first automatic transmission service interval is at the first maintenance service performed on the vehicle. At that time, change the external spin-on filter only. At every 83,000 km (50,000 miles) (normal service) or every 41,500 km (25,000 miles) (severe service), change the external spin-on filter and fluid. The sump filter is to be changed only during an overhaul. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Allison Fluid Filter - A/T: Service and Repair Allison Automatic Transmission Fluid/Filter Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Important: DO NOT drain the fluid if only the control main filter is being replaced. Remove drain plug (6) and drain plug seal (5). Drain the transmission fluid into a suitable container. 2. Inspect the drained fluid. 3. Important: Use a standard strap-type filter wrench to remove the control main filter. Remove filter (4) by rotating it in the counterclockwise direction. 4. Remove the magnet (2) from the filter attachment tube (1) in the converter housing or from the top of the control main filter (3). 5. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate that transmission replacement or overhaul is required. Installation Procedure 1. Reinstall the magnet (2) onto the filter attachment tube (1) which is in the converter housing. 2. Lubricate the gasket (3) on the control main filter with transmission fluid. 3. Install, by hand, the control main filter (4) until the gasket on the control main filter touches the converter housing. 4. Notice: Turning the control-main filter more than ONE FULL TURN after gasket contact will damage the filter and may cause fluid leakage. Turn the filter ONE FULL TURN ONLY after gasket contact. 5. Notice: Refer to Fastener Notice in Service Precautions. Reinstall the drain plug (6) and drain plug seal (5). ^ Tighten the drain plug to 35 Nm (26 ft. lbs.). 6. Refill Transmission with DEXRON®III Automatic Transmission Fluid. Refer to Fluid Capacity Specifications. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Allison > Page 2264 7. Important: DTC P0701 may often set following fluid service. Cycling the ignition clears the code and allows Drive or Reverse range to be attained. Cycle the ignition until Drive or Reverse range is attained. 8. Important: Fluid remains in the external circuits and transmission cavities after draining the transmission. Check the transmission fluid level. Control Main Filter Attachment Tube Control Main Filter Attachment Tube Replacement Removal Procedure Important: ^ DO NOT drain the fluid if only the control main filter attachment tube is being replaced. ^ Use a standard strap-type filter wrench to remove or install the control main filter. 1. Remove filter (4) by rotating it in the counterclockwise direction. 2. Remove the magnet (2) from the filter attachment tube (1) in the converter housing or from the filter element. 3. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate that transmission replacement or overhaul is required. 4. Remove the filter attachment tube (1) from the converter housing. Installation Procedure 1. Install the filter attachment tube (1). Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the attachment tube to 30 Nm (22 ft. lbs.). 2. Reinstall the magnet (2) onto the filter attachment tube (1). 3. Lubricate the gasket (3) on the control main filter with transmission fluid. 4. Install, by hand, the control main filter (4) until the gasket on the control main filter touches the converter housing. 5. Notice: Turning the control-main filter more than ONE FULL TURN after gasket contact will damage the filter and may cause fluid leakage. Turn the filter ONE FULL TURN ONLY after gasket contact. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Allison > Page 2265 6. Notice: Use only clean and approved transmission fluid. Check the transmission fluid level. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Allison > Page 2266 Fluid Filter - A/T: Service and Repair 4L80-E/4L85-E Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. Allow the transmission fluid to drain completely. 5. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the treads of the drain plug, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 7. Remove the drain pan from under the transmission oil pan. 8. Support the transmission with a transmission jack. 9. Remove the transmission mount nuts. 10. Remove the transmission support bolts and nuts. 11. Remove the transmission support side bracket bolts and bracket. 12. Remove the transmission support. 13. Disconnect the range selector cable end (2) from the transmission range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Allison > Page 2267 14. Important: It is not necessary to remove the selector cable from the bracket. Remove the transmission range selector cable bracket (2) bolts and bracket from the transmission. Reposition the bracket with cable. 15. Remove the oil pan bolts. 16. Important: The transmission oil pan gasket is reusable. Inspect the gasket and replace as needed. Remove the oil pan and gasket. 17. Remove the magnet from the bottom of the pan, if necessary. 18. Remove the oil filter. 19. Remove the filter neck seal. 20. Clean the transmission case and the oil pan gasket surfaces with solvent. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Allison > Page 2268 1. Install the filter neck seal. 2. Install the oil filter. 3. Install the oil pan gasket to the pan. 4. Install the magnet into the bottom of the pan, if necessary. 5. Install the oil pan and bolts. ^ Tighten the oil pan bolts to 24 Nm (18 ft. lbs.). 6. Position the bracket with cable. Install the transmission range selector cable bracket (2) and bolts to the transmission. ^ Tighten the selector bracket bolts to 25 Nm (18 ft. lbs.). 7. Connect the range selector cable end (2) to the transmission range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Allison > Page 2269 8. Install the transmission support. 9. Install the transmission support side bracket and bolts. 10. Install the transmission support bolts and nuts. ^ Tighten the bolts/nuts to 95 Nm (70 ft. lbs.). 11. Install the transmission mount nuts. ^ Tighten the nuts to 40 Nm (30 ft. lbs.). 12. Remove the transmission jack. 13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON® III transmission fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Improved Fuel Filter Design Fuel Filter: Technical Service Bulletins Fuel System - Improved Fuel Filter Design INFORMATION Bulletin No.: 04-06-04-070B Date: March 02, 2009 Subject: Information on Improved Fuel Filter for 6.6L Duramax(TM) Diesel Engine Models: 2001-2009 Chevrolet Silverado 2003-2009 Chevrolet Kodiak 2006-2009 Chevrolet Express 2001-2009 GMC Sierra 2003-2009 GMC TopKick 2006-2009 GMC Sierra Equipped with 6.6L Duramax(TM) Diesel Engine (VINs 1, 2, D, 6 - RPOs LB7, LLY, LBZ, LMM) Supercede: This bulletin is being revised to provide additional information to the field on fuel filter applications for the Duramax diesel engine. Please discard Corporate Bulletin Number 04-06-04-070A (Section 06 - Engine/Propulsion System). Important: It is acceptable to use diesel fuel containing up to 5% biodiesel (B5). Higher concentration (i.e., greater than B5) biodiesel-containing fuels or the use of unmodified bio-oils blended into diesel fuel at any concentration is not recommended and could damage the fuel system and engine. Such damage would not be covered by your warranty. A revised fuel filter is released that will service all 2001-2009 Chevrolet and GMC C/K models and 2003-2009 Chevrolet and GMC C4500/5500 Series vehicles with the 6.6L Duramax(TM) Diesel. The new coalescer filter provides the following benefits / improvements over the existing dual pleat design: ^ 150-200% increase in service life, depending on contaminant type Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Improved Fuel Filter Design > Page 2274 ^ Improved fuel system protection with some premium diesel and B5 biodiesel blends ^ Equivalent coarse water droplet removal efficiency of previous design ^ Greatly improved removal of emulsified water - a major contributor to fuel system issues Proper fuel filter servicing and the use of clean diesel fuel that is free of water or contaminants are critical for the longevity of fuel system components of a modern direct injected diesel engine. Adherence to the fuel filter change interval will help to ensure that the Duramax fuel system will be protected from contaminants and that the engine will continue to operate as designed. Purchasing fuel from a high volume fuel retailer increases the chances that the fuel is fresh and of good quality. Parts Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Page 2275 Fuel Filter: Locations FUEL FILTER/HEATER ELEMENT HOUSING Fuel Filter/Heater Element Housing Water In Fuel Sensor The Fuel Filter/Heater Element Housing is located on the right engine rocker cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Page 2276 Fuel Filter: Description and Operation FUEL FILTER The fuel filter is located on the rocker cover. The paper filter element traps particles in the fuel that may damage the fuel injection system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly Fuel Filter: Service and Repair Fuel Filter Assembly FUEL FILTER ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Drain the fuel from the fuel filter. Refer to Water-in-Fuel Draining Procedure. 2. Reposition the fuel hose clamps. 3. Remove the fuel hoses. 4. Disconnect the fuel filter electrical connectors. 5. Remove the fuel filter bracket bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 2279 6. Remove the fuel filter assembly. 7. Remove the fuel filter bracket bolts and bracket from the fuel filter/heater element housing. 8. Remove the fuel filter from the fuel filter/heater element housing. 9. Inspect the fuel filter, replace if necessary. INSTALLATION PROCEDURE 1. Install the fuel filter to the fuel filter/heater element housing. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel filter bracket and bolts to the fuel filter/heater element housing. Tighten Tighten the bolts to 20 N.m (15 lb ft). 3. Install the fuel filter assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 2280 4. Install the fuel filter bracket bolts. Tighten Tighten the bolts to 20 N.m (15 lb ft). 5. Connect the fuel filter electrical connectors. 6. Install the fuel hoses. 7. Position the fuel hose clamps. 8. Prime the fuel system. Refer to Fuel System Priming. 9. Start the engine. If the engine stalls, repeat the above step. 10. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 2281 Fuel Filter: Service and Repair Fuel Filter Element FUEL FILTER REPLACEMENT REMOVAL PROCEDURE 1. Drain the fuel from the fuel filter. Refer to Water-in-Fuel Draining Procedure. 2. Reposition the fuel hose clamps. 3. Remove the fuel hoses. 4. Disconnect the fuel filter connectors. 5. Unscrew the fuel filter from the fuel filter adapter. 6. Remove the water-in-fuel sensor from the fuel filter. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 2282 1. Install the water-in-fuel sensor to the NEW fuel filter. IMPORTANT: Inspect the fuel heater element housing for contamination. Contamination on the fuel heater element housing may cause leakage at the fuel filter. Coat the fuel filter seal with clean engine oil. 2. Screw on the NEW fuel filter to the fuel filter adapter. 3. Connect the fuel filter connectors. 4. Install the fuel hoses. 5. Position the fuel hose clamps. 6. Prime the fuel system. Refer to Fuel System Priming. 7. Start the engine. If the engine stalls, repeat the above step. 8. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 2283 Fuel Filter: Service and Repair Fuel Filter Life Reset FUEL FILTER LIFE RESET This message will appear when a reset is performed either by using the steering wheel controls or the following manual procedure. For vehicles with steering wheel controls: 1. Reset the fuel filter monitor. 2. Press and hold the select button for five seconds while the "FUEL FILTER LIFE" message is displayed. This message will appear on the DIC for ten seconds. For vehicles without steering wheel controls, do the following: 1. Without pressing the pedals, turn the ignition key to the "ON" position without starting the engine. 2. Wait five seconds. 3. Completely press the brake and the accelerator pedals simultaneously and hold for ten seconds. The system is now reset. 4. Turn the ignition key off. The next time the engine is started, the message will no longer be displayed. Always reset the FUEL FILTER LIFE system after a fuel filter change. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 2284 Fuel Filter: Service and Repair Fuel System Priming FUEL SYSTEM PRIMING IMPORTANT: In order for the DURAMAX diesel engine fuel system to work properly, the fuel lines must be full of fuel and contain no air. If air gets into the fuel lines, it will be necessary to prime the fuel system to eliminate the air before operating the vehicle. Air could have entered to system in one of the following ways: - The vehicle ran out of fuel. - The filter was removed for service or replacement. - The fuel lines were removed or disconnected for servicing. - The fuel filter water drain cock was opened while the engine was running. If one or more of the above occurred, air has entered the fuel system and you will need to prime the system prior to operating the vehicle. 1. Prior to priming the engine, ensure that the following is complete: - There is fuel in the fuel tank. - The fuel filter has been installed and properly tightened. - The fuel lines are properly connected. - The fuel filter is cool to the touch. - Any dirt or debris is removed from the fuel filter head and vent valve. 2. Open the vent valve by turning the screw counterclockwise several full turns. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 2285 3. Operate the priming pump until a small amount of fuel seeps from the vent valve. allow the pump to return upwards between pumps. When fuel is present, the filter is full of fuel and the system should be primed. 4. Close the vent valve. 5. Clean any fuel which accumulated on the fuel filter. 6. Start the engine and allow it to idle for a few minutes. 7. Check the filter for leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 2290 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. 2. Place a suitable container under the oil pan to drain the oil into. 3. Remove the oil drain plug. 4. Drain the engine oil. 5. Remove the oil filter. 6. Inspect to ensure the engine oil filter gasket is removed. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 2291 1. Lubricate the oil filter seal with clean engine oil. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil filter. Tighten the filter after contact plus 1 to 11⁄4 turn. 3. Install the oil pan drain plug. Tighten the plug to 84 Nm (62 ft. lbs.). 4. Lower the vehicle. 5. Fill the engine with the proper capacity and quality of engine oil. Refer to Capacities - Approximate Fluid in Maintenance and Lubrication. 6. Operate the engine, check for oil leaks, and normal oil pressure. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Filter: > 03-01-38-019A > Sep > 04 > A/C - Underhood Rattle Noise on Hard Acceleration Refrigerant Filter: Customer Interest A/C - Underhood Rattle Noise on Hard Acceleration File In Section: 01 - HVAC Bulletin No.: 03-01-38~019A Date: September, 2004 TECHNICAL Subject: Underhood Rattle Noise Heard On Acceleration (Check A/C System Performance and Compressor Operation) Models: 2003-2004 Cadillac CTS 2002-2004 Cadillac Escalade, Escalade EXT 2003-2004 Cadillac Escalade ESV 2002-2004 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2002-2004 GMC Denali, Denali XL, Savana, Sierra, Yukon, Yukon XL 2002-2004 Commercial Upfitter Chassis Vehicles with Air Conditioning (A/C) This bulletin is being revised to update the service procedure and parts information. Please discard Corporate Bulletin Number 03-01-38-019 (Section 01 - HVAC). Condition Some customers may comment about an underhood rattle noise heard on acceleration or a sudden loss of A/C system performance. Cause This condition may be caused by liquid slugging of the A/C compressor. This condition may cause an internal failure in the A/C compressor. The serpentine belt tensioner and serpentine belt may also be damaged. Correction Technicians are to check the A/C system performance and compressor operation using the following repair procedure: 1. Open the hood and inspect the A/C compressor for damage and to see if the compressor is seized. Verify that the serpentine belt is not damaged or missing. If the A/C compressor is seized, proceed to Step 5. 2. Perform the A/C System Performance test. Refer to the Heating, Ventilation and Air Conditioning (HVAC) section of SI. Correct any performance concerns or refrigerant leaks that are found. 3. Inspect the vehicle for other possible sources of A/C compressor noise or performance concerns. Refer to Corporate Bulletin Number 01-01-38-013 for more information. 4. After all other possible sources of A/C compressor noise or performance concerns have been eliminated, only then should the A/C compressor be replaced. 5. Remove the A/C compressor. Refer to the A/C Compressor Replacement procedure in the HVAC section of SI. 6. Inspect the transmission cooler lines for damage due to contact from the serpentine belt. Replace the transmission cooler lines if necessary. 7. Install an inline A/C system filter. Refer to Corporate Bulletin Number 01-01-38-006C for more information about A/C system flushing and filter installation procedures. An A/C system flush is not to be done unless prior authorization is given by the GM Area Service Manager (in Canada, the District Service Manager). 8. Install an A/C Suction Screen. Refer to Corporate Bulletin Number 01-01-39-003A for more information about A/C suction screen repair recommendations and procedures. 9. Install a new A/C compressor. Refer to the Compressor Replacement procedure in the HVAC section of SI. 10. Install a new orifice tube for the front A/C system. Refer to the Expansion (Orifice) Tube Replacement procedure in SI. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Filter: > 03-01-38-019A > Sep > 04 > A/C - Underhood Rattle Noise on Hard Acceleration > Page 2300 11. If the vehicle is a 2003 model year Chevrolet Express or GMC Savana van, the vehicle may require a new accumulator. Refer to Corporate Bulletin Number 03-01-38-016 for more information. This bulletin refers to an updated design accumulator that may improve the performance of the A/C system. 12. Install a new serpentine belt tensioner and serpentine belt if they have been damaged due to A/C system slugging or an A/C compressor seizure. The serpentine belt tensioner may have broken stop tabs and/or a missing front cap. 13. Verify proper operation of the A/C system. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Filter: > 03-01-38-019A > Sep > 04 > A/C - Underhood Rattle Noise on Hard Acceleration Refrigerant Filter: All Technical Service Bulletins A/C - Underhood Rattle Noise on Hard Acceleration File In Section: 01 - HVAC Bulletin No.: 03-01-38~019A Date: September, 2004 TECHNICAL Subject: Underhood Rattle Noise Heard On Acceleration (Check A/C System Performance and Compressor Operation) Models: 2003-2004 Cadillac CTS 2002-2004 Cadillac Escalade, Escalade EXT 2003-2004 Cadillac Escalade ESV 2002-2004 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2002-2004 GMC Denali, Denali XL, Savana, Sierra, Yukon, Yukon XL 2002-2004 Commercial Upfitter Chassis Vehicles with Air Conditioning (A/C) This bulletin is being revised to update the service procedure and parts information. Please discard Corporate Bulletin Number 03-01-38-019 (Section 01 - HVAC). Condition Some customers may comment about an underhood rattle noise heard on acceleration or a sudden loss of A/C system performance. Cause This condition may be caused by liquid slugging of the A/C compressor. This condition may cause an internal failure in the A/C compressor. The serpentine belt tensioner and serpentine belt may also be damaged. Correction Technicians are to check the A/C system performance and compressor operation using the following repair procedure: 1. Open the hood and inspect the A/C compressor for damage and to see if the compressor is seized. Verify that the serpentine belt is not damaged or missing. If the A/C compressor is seized, proceed to Step 5. 2. Perform the A/C System Performance test. Refer to the Heating, Ventilation and Air Conditioning (HVAC) section of SI. Correct any performance concerns or refrigerant leaks that are found. 3. Inspect the vehicle for other possible sources of A/C compressor noise or performance concerns. Refer to Corporate Bulletin Number 01-01-38-013 for more information. 4. After all other possible sources of A/C compressor noise or performance concerns have been eliminated, only then should the A/C compressor be replaced. 5. Remove the A/C compressor. Refer to the A/C Compressor Replacement procedure in the HVAC section of SI. 6. Inspect the transmission cooler lines for damage due to contact from the serpentine belt. Replace the transmission cooler lines if necessary. 7. Install an inline A/C system filter. Refer to Corporate Bulletin Number 01-01-38-006C for more information about A/C system flushing and filter installation procedures. An A/C system flush is not to be done unless prior authorization is given by the GM Area Service Manager (in Canada, the District Service Manager). 8. Install an A/C Suction Screen. Refer to Corporate Bulletin Number 01-01-39-003A for more information about A/C suction screen repair recommendations and procedures. 9. Install a new A/C compressor. Refer to the Compressor Replacement procedure in the HVAC section of SI. 10. Install a new orifice tube for the front A/C system. Refer to the Expansion (Orifice) Tube Replacement procedure in SI. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Filter: > 03-01-38-019A > Sep > 04 > A/C - Underhood Rattle Noise on Hard Acceleration > Page 2306 11. If the vehicle is a 2003 model year Chevrolet Express or GMC Savana van, the vehicle may require a new accumulator. Refer to Corporate Bulletin Number 03-01-38-016 for more information. This bulletin refers to an updated design accumulator that may improve the performance of the A/C system. 12. Install a new serpentine belt tensioner and serpentine belt if they have been damaged due to A/C system slugging or an A/C compressor seizure. The serpentine belt tensioner may have broken stop tabs and/or a missing front cap. 13. Verify proper operation of the A/C system. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Installation Refrigerant Filter: Service and Repair Installation AIR CONDITIONING (A/C) REFRIGERANT FILTER INSTALLATION TOOLS REQUIRED J 39400-A Halogen Leak Detector IMPORTANT: The A/C Refrigerant filter, ACDelco P/N 15-1696 must be installed to the A/C evaporator tube between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Remove the air cleaner. 2. Measure 50 mm (2 in) from the bend on the evaporator tube (2) near the expansion tube end and mark the location. 3. Measure 50.8 mm (2 in) from the mark on the evaporator tube (2) from the previous step. IMPORTANT: Do not allow metal burrs to enter the evaporator tube (2) during cutting or when removing the burrs. 4. Using a tubing cutter, cut the marked section of the evaporator tube (2). 5. Remove the burrs from the evaporator tube (2). 6. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). IMPORTANT: DO NOT install the O-rings (2) in this step. 7. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves. 8. Install the ferrules (3) with the small end toward the nut (4). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Installation > Page 2309 9. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 10. While holding the evaporator tube in the A/C refrigerant filter (1), tighten the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 11. Remove the nuts (4) from the A/C refrigerant filter (1). 12. Coat the O-rings (2) with 525 viscosity refrigerant oil. 13. Install the O-rings (2) to the evaporator tube halves. 14. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 15. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 16. Leak test the fittings of the component using the J 39400-A. 17. Install the air cleaner. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Installation > Page 2310 Refrigerant Filter: Service and Repair Replacement AIR CONDITIONING (A/C) REFRIGERANT FILTER REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. IMPORTANT: The nuts (4) and the ferrules (3) will remain on the evaporator tube. Do not try to remove. 3. Remove the nuts (4) from the A/C refrigerant filter (1). 4. Remove the A/C refrigerant filter (3) from the evaporator tube (2). INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Installation > Page 2311 1. Coat the O-rings (2) with 525 viscosity refrigerant oil. 2. Install the O-rings (2) to the evaporator tube. 3. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 5. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Installation > Page 2312 6. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 7. Install the air cleaner. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement Coolant Line/Hose: Service and Repair Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement (6.6L (LLY) Engine) Removal Procedure 1. Remove the intake manifold cover. 2. Remove the air cleaner outlet duct. 3. Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting. Loosen the charged air cooler outlet duct to intake hose clamp. 4. Remove the charged air cooler outlet duct from the intake. 5. Remove the tie strap from the electrical harness. 6. Reposition the engine harness from the air inlet tube. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 2318 7. Remove the air inlet tube nuts. 8. Remove the air inlet tube. 9. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 10. Reposition the Exhaust Gas Recirculation (EGR) coolant pipe hose clamp. 11. Remove the EGR coolant pipe hose. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 2319 12. Remove the EGR coolant pipe bolts. 13. Remove the EGR coolant pipe. 14. Remove and discard the coolant pipe O-ring seal. Installation Procedure 1. Install a NEW O-ring seal onto the coolant pipe. Lubricate the seal with engine coolant. 2. Install the EGR coolant pipe. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the EGR coolant pipe bolts. Tighten the bolts to 25 Nm (18 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 2320 4. Install the EGR coolant pipe hose. 5. Position the EGR coolant pipe hose clamp. 6. Connect the ECT sensor electrical connector. 7. Install the air inlet tube. 8. Install the air inlet tube nuts. Tighten the nuts to 25 Nm (18 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 2321 9. Position the engine harness to the air inlet tube. 10. Install a NEW tie strap. 11. Important: Lubricate the end of the duct prior to installation. Install the charged air cooler outlet duct to the intake. 12. Tighten the charged air cooler outlet duct to intake hose clamp. Tighten the clamp to 6 Nm (53 inch lbs.). 13. Install the air cleaner outlet duct. 14. Install the intake manifold cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 2322 Coolant Line/Hose: Service and Repair Turbocharger Coolant Hoses/Pipes Replacement Engine - Inlet Pipe Turbocharger Coolant Hoses/Pipes Replacement (6.6L (LLY) Engine - Inlet Pipe) Removal Procedure 1. Remove the intake manifold cover. 2. Drain the cooling system. 3. Important: After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1). Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting. 4. Remove the charged air cooler inlet duct connector (4) from the turbocharger. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 2323 5. Reposition the turbocharger coolant inlet hose clamp at the bypass valve. 6. Remove the turbocharger coolant inlet hose banjo bolt (1). 7. Remove the inlet hose washer and inlet line. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 2324 1. Install the inlet hose washer and inlet line. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the turbocharger coolant inlet hose banjo bolt (1). Tighten the bolt to 25 Nm (18 ft. lbs.). 3. Position the turbocharger coolant inlet hose clamp at the bypass valve. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 2325 4. Remove the tape from the turbocharger openings. 5. Important: Lubricate the end of the duct prior to installation. Install the charged air cooler inlet duct connector (4) to the turbocharger. 6. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1). Tighten the clamp to 6 Nm (53 inch lbs.). 7. Fill the cooling system. 8. Install the intake manifold cover Engine - Outlet Pipe Turbocharger Coolant Hoses/Pipes Replacement (6.6L (LLY) Engine - Outlet Pipe) Removal Procedure 1. Remove the intake manifold cover. 2. Drain the cooling system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 2326 3. Disconnect the negative battery cables. 4. Remove the air cleaner outlet duct. 5. Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damage. Loosen the hose by twisting. Loosen the charged air cooler outlet duct to intake hose clamp. 6. Remove the charged air cooler duct from the intake. 7. Remove the generator mounting bracket. 8. Remove the Exhaust Gas Recirculation (EGR) cooler tube. 9. Disconnect the fuel injection control module electrical connectors. 10. Remove the upper fuel injection control module fuel line bolt. 11. Remove and discard the washer from the banjo fitting. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 2327 12. Reposition the hose clamp at the bypass pipe. 13. Remove the turbocharger coolant outlet hose from the bypass pipe. 14. Reposition the turbocharger coolant outlet hose clamp. 15. Remove the turbocharger coolant outlet hose from the pipe on the turbocharger. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 2328 16. Remove the turbocharger coolant outlet pipe bolt and nut. 17. If necessary, remove the turbocharger. 18. If necessary, remove the coolant outlet pipe clip bolt (3) from the turbocharger. 19. If necessary, remove the coolant outlet pipe. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 2329 1. If necessary, install the coolant outlet pipe. 2. Notice: Refer to Fastener Notice in Service Precautions. If necessary, install the coolant outlet pipe clip bolt (3) to the turbocharger. Tighten the bolt to 9 Nm (80 inch lbs.). 3. If necessary, install the turbocharger. 4. Install the turbocharger coolant outlet pipe bolt and nut. Tighten the bolt/nut to 9 Nm (80 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 2330 5. Install the turbocharger coolant outlet hose to the pipe on the turbocharger. 6. Position the turbocharger coolant outlet hose clamp. 7. Install the turbocharger coolant outlet hose to the bypass pipe. 8. Position the hose clamp at the bypass pipe. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 2331 9. Install a NEW washer to the banjo fitting. 10. Install the upper fuel injection control module fuel line bolt. Tighten the bolt to 35 Nm (26 ft. lbs.). 11. Connect the fuel injection control module electrical connectors. 12. Install the EGR cooler tube. 13. Install the generator mounting bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 2332 14. Important: Lubricate the end of the duct prior to installation. Install the charged air cooler duct to the intake. 15. Tighten the charged air cooler outlet duct to intake hose clamp. Tighten the clamp to 6 Nm (53 inch lbs.). 16. Install the air cleaner outlet duct. 17. Connect the negative battery cables. 18. Fill the cooling system. 19. Install the intake manifold cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 2333 Coolant Line/Hose: Service and Repair Water Pump Outlet Pipe Replacement Water Pump Outlet Pipe Replacement (6.6L (LLY) Engine) Removal Procedure 1. Remove the water pump. 2. Remove the engine coolant pipe. 3. Remove and discard the coolant pipe O-ring seal. Installation Procedure 1. Install a NEW O-ring seal onto the coolant pipe. 2. Lubricate the O-ring seal with engine coolant. 3. Install the engine coolant pipe. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 2334 4. Install the water pump. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet (With RPO Code HP2 Front) Heater Hose: Service and Repair Heater Hose Replacement - Inlet (With RPO Code HP2 Front) HEATER HOSE REPLACEMENT - INLET (W/ HP2 FRONT) REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Loosen the air cleaner outlet duct clamps at the following locations: - Throttle body - Mass airflow/intake air temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet duct. 4. Remove the air cleaner outlet duct. 5. Reposition the inlet heater hose clamp from the engine. 6. Remove the inlet heater hose from the engine. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet (With RPO Code HP2 Front) > Page 2339 7. Reposition the inlet heater hose clamp (4) from the auxiliary water pump (1). 8. Remove the inlet heater hose (6) from the auxiliary water pump (1). INSTALLATION PROCEDURE 1. Install the inlet heater hose (6) to the auxiliary water pump (1). 2. Position the inlet heater hose clamp (4) to the auxiliary water pump (1). 3. Install the inlet heater hose to the engine. 4. Position the inlet heater hose clamp to the engine. IMPORTANT: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet (With RPO Code HP2 Front) > Page 2340 5. Install the air cleaner outlet duct. 6. Install the radiator inlet hose clip to the outlet duct. NOTE: Refer to Fastener Notice in Service Precautions. 7. Tighten the air cleaner outlet duct clamps at the following locations: - Throttle body - MAF/IAT sensor Tighten Tighten the screws to 7 N.m (62 lb in). 8. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet (With RPO Code HP2 Front) > Page 2341 Heater Hose: Service and Repair Heater Hose Replacement - Inlet (With RPO Code HP2 Rear) HEATER HOSE REPLACEMENT - INLET (W/ HP2 REAR) TOOLS REQUIRED J 43181 Quick Connect Connector Removal Tool REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Using the J 43181 disconnect the heater hose from the heater core inlet. 2.1. Install the J 43181 to the heater core pipe. 2.2. Close the tool around the heater core pipe. 2.3. Firmly pull the tool into the quick connect end of the heater hose. 2.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 3. Reposition the inlet heater hose clamp (2) from the auxiliary water pump (1). 4. Remove the inlet heater hose (3) from the auxiliary water pump (1). INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet (With RPO Code HP2 Front) > Page 2342 1. Install the inlet heater hose (3) to the auxiliary water pump (1). 2. Position the inlet heater hose clamp (2) to the auxiliary water pump (1). 3. Connect the inlet heater hose to the heater core. 4. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 5. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough Hose/Line HVAC: Customer Interest A/C - Doesn't Blow Cold Enough Bulletin No.: 02-01-38-007C Date: July 27, 2004 TECHNICAL Subject: Poor A/C Performance - A/C Will Not Blow Cold Enough (Perform A/C System Checks, Replace Accumulator if Necessary) Models: 2002-2004 Chevrolet Silverado 2002-2004 GMC Sierra with 6.6L Diesel Engine (VINs 1, 2 - RPOs LB7, LLY) and Denso A/C Compressor Supercede: This bulletin is being revised to add part numbers for the hose, bracket and insulator to the Parts Information. Please discard Corporate Bulletin Number 02-01-38-007B (Section 01 - HVAC). Condition Some customers may comment on less than desirable A/C performance, especially when the ambient temperature is above 32°C (90°F). Correction Perform the following A/C system checks and replace the accumulator with P/N 89018601, if necessary. This new accumulator requires the accumulator bracket, the accumulator insulator and the A/C suction hose to be replaced also. ^ Check for A/C system leaks. ^ Check the A/C system for proper refrigerant charge. This requires recovering the refrigerant to determine charge in system. Refer to Refrigerant Recovery and Recharging in the HVAC sub-section of the Service Manual. ^ If no leaks were found and the A/C system is charged to specification, replace the accumulator using the procedure listed below. If normal diagnostics do not lead to a correction, then perform the following A/C system checks. 1. Re-calibrate the actuators. 2. Inspect the lower A/C condenser deflector for proper installation. The deflector should be positioned at the lower part of the condenser and extend forward into the top of the front bumper and below the two fresh air intake holes. 3. Check the engine cooling fan clutch for proper operation. 4. If the vehicle is equipped with a front license plate, inspect for proper installation. If the license plate bracket is installed upside down, it will block part of the two fresh air intake holes in the bumper. When the license plate bracket is installed correctly, the writing on the back of the bracket will be upside down. Inspect for material between the radiator and condenser. Remove the top plate to confirm that there is no restriction. A radiator front filled with material will decrease condenser performance. 5. Some improvements have been found by lowering the A/C charge from 0.82 kg (1.8 lbs) to 0.73 kg (1.6 lbs). 6. Check the low pressure cycling switch for proper operation. The low pressure switch opens at 172-234 kPa (25-34 psi) which stops compressor operation and closes when the low side pressure reaches 276-310 kPa (40-45 psi). This enables the compressor to turn back on. Important: Compressor clutch engagement cannot be used to determine the status of the low pressure switch. The low pressure switch is one of several inputs to the HVAC control module for A/C request authorization. A/C request is one of several inputs to the powertrain control module (PCM) that control A/C compressor clutch engagement. Using a scan tool to monitor low pressure switch status while monitoring the low side pressure with the ACR 2000 at the service port and watch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough > Page 2351 the pressure at which the switch opens/closes is imperative to successfully diagnosing the switch. 7. If the A/C performance has not improved after performing the above steps, replace the accumulator with P/N 89018601, using the procedure listed below. This new accumulator also requires the accumulator bracket, accumulator insulator and A/C suction hose to be replaced. Accumulator Replacement 1. Remove the suction hose mounting bolt from the A/C compressor. 2. Remove the suction hose from the compressor. 3. Remove the suction hose nut from the accumulator. 4. Remove the suction hose from the accumulator. 5. Remove the evaporator tube nut from the evaporator. 6. Remove the evaporator tube from the evaporator. 7. Disconnect the electrical connector from the A/C low pressure switch. 8. Remove the nut from the evaporator fitting. 9. Remove the accumulator bracket nut from the retaining stud. 10. Remove the accumulator. 11. Remove the retaining bracket bolt. This bolt must be reused for the new bracket. 12. Remove the insulator. One half of the insulator must be reused. 13. Install the new insulator and one half of the old insulator onto the new accumulator. 14. Install the new retaining bracket and bolt to the accumulator. Do not tighten at this time. 15. Add the PAG oil directly into the new accumulator that was removed during the recovery process plus an additional 90 ml (3 oz). 16. Install the new accumulator. 17. Install the accumulator bracket nut. Tighten Tighten the nut to 9 N.m (80 lb in). 18. Tighten the retaining bracket bolt. Tighten Tighten the nut to 10 N.m (89 lb in). 19. Install the nut to the evaporator fitting. Tighten Tighten the nut to 16 N.m (12 lb ft). 20. Install the evaporator tube to the evaporator. 21. Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N.m (12 lb ft). 22. Install the new suction hose to the accumulator. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough > Page 2352 23. Install the suction hose nut to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft). 24. Connect the electrical connector to the A/C low pressure switch. 25. Install the new suction hose to the compressor. 26. Install the suction hose mounting bolt to the A/C compressor. Tighten Tighten the bolt to 16 N.m (12 lb ft). Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough Hose/Line HVAC: All Technical Service Bulletins A/C - Doesn't Blow Cold Enough Bulletin No.: 02-01-38-007C Date: July 27, 2004 TECHNICAL Subject: Poor A/C Performance - A/C Will Not Blow Cold Enough (Perform A/C System Checks, Replace Accumulator if Necessary) Models: 2002-2004 Chevrolet Silverado 2002-2004 GMC Sierra with 6.6L Diesel Engine (VINs 1, 2 - RPOs LB7, LLY) and Denso A/C Compressor Supercede: This bulletin is being revised to add part numbers for the hose, bracket and insulator to the Parts Information. Please discard Corporate Bulletin Number 02-01-38-007B (Section 01 - HVAC). Condition Some customers may comment on less than desirable A/C performance, especially when the ambient temperature is above 32°C (90°F). Correction Perform the following A/C system checks and replace the accumulator with P/N 89018601, if necessary. This new accumulator requires the accumulator bracket, the accumulator insulator and the A/C suction hose to be replaced also. ^ Check for A/C system leaks. ^ Check the A/C system for proper refrigerant charge. This requires recovering the refrigerant to determine charge in system. Refer to Refrigerant Recovery and Recharging in the HVAC sub-section of the Service Manual. ^ If no leaks were found and the A/C system is charged to specification, replace the accumulator using the procedure listed below. If normal diagnostics do not lead to a correction, then perform the following A/C system checks. 1. Re-calibrate the actuators. 2. Inspect the lower A/C condenser deflector for proper installation. The deflector should be positioned at the lower part of the condenser and extend forward into the top of the front bumper and below the two fresh air intake holes. 3. Check the engine cooling fan clutch for proper operation. 4. If the vehicle is equipped with a front license plate, inspect for proper installation. If the license plate bracket is installed upside down, it will block part of the two fresh air intake holes in the bumper. When the license plate bracket is installed correctly, the writing on the back of the bracket will be upside down. Inspect for material between the radiator and condenser. Remove the top plate to confirm that there is no restriction. A radiator front filled with material will decrease condenser performance. 5. Some improvements have been found by lowering the A/C charge from 0.82 kg (1.8 lbs) to 0.73 kg (1.6 lbs). 6. Check the low pressure cycling switch for proper operation. The low pressure switch opens at 172-234 kPa (25-34 psi) which stops compressor operation and closes when the low side pressure reaches 276-310 kPa (40-45 psi). This enables the compressor to turn back on. Important: Compressor clutch engagement cannot be used to determine the status of the low pressure switch. The low pressure switch is one of several inputs to the HVAC control module for A/C request authorization. A/C request is one of several inputs to the powertrain control module (PCM) that control A/C compressor clutch engagement. Using a scan tool to monitor low pressure switch status while monitoring the low side pressure with the ACR 2000 at the service port and watch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough > Page 2358 the pressure at which the switch opens/closes is imperative to successfully diagnosing the switch. 7. If the A/C performance has not improved after performing the above steps, replace the accumulator with P/N 89018601, using the procedure listed below. This new accumulator also requires the accumulator bracket, accumulator insulator and A/C suction hose to be replaced. Accumulator Replacement 1. Remove the suction hose mounting bolt from the A/C compressor. 2. Remove the suction hose from the compressor. 3. Remove the suction hose nut from the accumulator. 4. Remove the suction hose from the accumulator. 5. Remove the evaporator tube nut from the evaporator. 6. Remove the evaporator tube from the evaporator. 7. Disconnect the electrical connector from the A/C low pressure switch. 8. Remove the nut from the evaporator fitting. 9. Remove the accumulator bracket nut from the retaining stud. 10. Remove the accumulator. 11. Remove the retaining bracket bolt. This bolt must be reused for the new bracket. 12. Remove the insulator. One half of the insulator must be reused. 13. Install the new insulator and one half of the old insulator onto the new accumulator. 14. Install the new retaining bracket and bolt to the accumulator. Do not tighten at this time. 15. Add the PAG oil directly into the new accumulator that was removed during the recovery process plus an additional 90 ml (3 oz). 16. Install the new accumulator. 17. Install the accumulator bracket nut. Tighten Tighten the nut to 9 N.m (80 lb in). 18. Tighten the retaining bracket bolt. Tighten Tighten the nut to 10 N.m (89 lb in). 19. Install the nut to the evaporator fitting. Tighten Tighten the nut to 16 N.m (12 lb ft). 20. Install the evaporator tube to the evaporator. 21. Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N.m (12 lb ft). 22. Install the new suction hose to the accumulator. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough > Page 2359 23. Install the suction hose nut to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft). 24. Connect the electrical connector to the A/C low pressure switch. 25. Install the new suction hose to the compressor. 26. Install the suction hose mounting bolt to the A/C compressor. Tighten Tighten the bolt to 16 N.m (12 lb ft). Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement (Without RPO Code HP2) Hose/Line HVAC: Service and Repair Evaporator Tube Replacement (Without RPO Code HP2) EVAPORATOR TUBE REPLACEMENT (W/O HP2) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Remove the evaporator tube nut from the evaporator. 3. Remove the evaporator tube from the evaporator. 4. Remove the right park/turn signal lamp. 5. Remove the grille from the vehicle. 6. Remove the evaporator tube nut from the condenser. 7. Remove the evaporator tube from the condenser. 8. Remove the evaporator tube from the vehicle. 9. Discard all of the used sealing washers. Cap all of the open connections. INSTALLATION PROCEDURE 1. Install the evaporator tube to the condenser using new sealing washers. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement (Without RPO Code HP2) > Page 2362 2. Install the evaporator tube nut to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft). 3. Install the grille to the vehicle. 4. Install the right park/turn signal lamp. 5. Install the evaporator tube to the evaporator. 6. Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N.m (12 lb ft). 7. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 8. Leak test the fittings of the components using the J 39400-A. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement (Without RPO Code HP2) > Page 2363 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement (With RPO Code HP2) EVAPORATOR TUBE REPLACEMENT (W/ HP2) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Remove the evaporator tube nut from the evaporator. 3. Remove the evaporator tube from the evaporator. 4. Loosen the nut from the evaporator tube fitting. 5. Remove the rear evaporator tube (3) from the vehicle. 6. Remove the air cleaner assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement (Without RPO Code HP2) > Page 2364 7. Remove the push pin from the right side radiator air baffle. 8. Remove the bolts (2) from the starter/generator control module (SGCM) coolant pump (1). 9. Reposition the SGCM coolant pump. 10. Remove the right park/turn signal lamp. 11. Remove the grille from the vehicle. 12. Remove the evaporator tube nut from the condenser. 13. Remove the evaporator tube from the condenser. 14. Remove the front evaporator tube from the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement (Without RPO Code HP2) > Page 2365 15. Discard all of the used sealing washers. Cap all of the open connections. INSTALLATION PROCEDURE 1. Install the front evaporator tube to the vehicle. 2. Uncap all of the open connections 3. Install the evaporator tube to the condenser using new sealing washers. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the evaporator tube nut to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft). 5. Install the grille to the vehicle. 6. Install the right park/turn signal lamp. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement (Without RPO Code HP2) > Page 2366 7. Position the SGCM coolant pump (1) to the radiator core support (3). 8. Install the bolts (2) to the SGCM coolant pump (1). Tighten Tighten the nut to 16 N.m (12 lb ft). 9. Install the push pin to the right side radiator air baffle. 10. Install the air cleaner assembly. 11. Install the rear evaporator tube (3) to the vehicle. 12. Connect the nut to the evaporator tube fitting. Tighten Tighten the nut to 9 N.m (80 lb in). 13. Install the evaporator tube to the evaporator. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement (Without RPO Code HP2) > Page 2367 14. Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N.m (12 lb ft). 15. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 16. Leak test the fittings of the components using the J 39400-A. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet Pipe/Hose (Rack and Pinion) Power Steering Gear Inlet Pipe/Hose Replacement (Rack and Pinion) Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Remove the power steering inlet hose (2) from the power steering pump (1). 2. Remove the power steering inlet hose (2) from the power steering gear (3). Installation Procedure 1. Connect the power steering inlet hose (2) to the power steering gear (3). 2. Notice: Refer to Fastener Notice in Service Precautions. Connect the power steering inlet hose (2) to the power steering pump (1). ^ Tighten the hose connections to 28 Nm (20 ft. lbs.). 3. Bleed the power steering system. Refer to Bleeding the Power Steering System. 4. Inspect all the hose connections for leaks. (With Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (With Hydroboost) Removal Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 2372 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the power steering gear inlet hose (1) from the brake booster. 3. Remove the power steering gear inlet hose from the power steering gear. 4. Remove the power steering gear inlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear inlet hose (1) to the brake booster (2). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear inlet hose to the power steering gear. ^ Tighten both power steering gear inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. (Without Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Without Hydroboost) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine protection shield. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 2373 3. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 4. Remove the power steering gear inlet hose (3) from the power steering pump (1). 5. Remove the power steering gear inlet hose from the power steering gear. 6. Remove the power steering gear inlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear inlet hose (3) to the power steering pump (1). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear inlet hose to the power steering gear. ^ Tighten both power steering gear inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Install the engine protection shield. 6. Lower the vehicle. 7. Bleed the power steering system. Refer to Bleeding the Power Steering System. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 2374 Power Steering Line/Hose: Service and Repair Power Steering Gear Outlet Pipe/Hose (Recirculating Ball) Power Steering Gear Outlet Pipe/Hose Replacement (Recirculating Ball) Removal Procedure 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the power steering gear outlet hose (3) from the steering gear (2). 3. Remove the clamp retaining the power steering gear outlet hose (3) to the power steering pump (1).Remove the power steering gear outlet hose from the power steering pump. 4. Remove the power steering gear outlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear outlet hose (3) to the power steering pump (1).Position the clamp at the end of the hose. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear outlet hose to the power steering gear. ^ Tighten the outlet hose fitting to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. (Rack and Pinion) Power Steering Gear Outlet Pipe/Hose Replacement (Rack and Pinion) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 2375 Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Remove the power steering outlet hose (4) from the power steering gear (3). 2. Remove the power steering outlet hose (4) from the power steering cooler (5). Installation Procedure 1. Connect the power steering outlet hose (4) to the power steering cooler (5). 2. Connect the power steering outlet hose (4) to the power steering gear (3). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Connect the power steering outlet hose (2) to the power steering pump (1). ^ Tighten both hose connections to 28 Nm (20 ft. lbs.). 4. Bleed the power steering system. Refer to Bleeding the Power Steering System. 5. Inspect all the hose connections for leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 2376 Power Steering Line/Hose: Service and Repair Power Brake Booster Inlet Hose Replacement Power Brake Booster Inlet Hose Replacement Removal Procedure 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the brake booster inlet hose (1) from the brake booster (2). 3. Remove the brake booster inlet hose from the power steering pump. 4. Remove the brake booster inlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the brake booster inlet hose (1) to the brake booster (2). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the brake booster inlet hose to the power steering pump. ^ Tighten the brake booster inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 2377 Power Steering Line/Hose: Service and Repair Power Brake Booster Outlet Hose Replacement Power Brake Booster Outlet Hose Replacement Removal Procedure 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the brake booster outlet hose (1) from the brake booster (2). 3. Remove the clamp retaining the brake booster outlet hose to the power steering pump. 4. Remove the brake booster outlet hose from the vehicle. Installation Procedure 1. Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. Route the hose in the same position the hose occupied prior to removal. 2. Install the brake booster outlet hose (1) to the brake booster (2).Position the clamp at the end of the hose. 3. Install the brake booster outlet hose to the power steering pump (4).Position the clamp at the end of the hose. 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 2378 Power Steering Line/Hose: Service and Repair (Rack and Pinion) Power Steering Gear Inlet Pipe/Hose Replacement (Rack and Pinion) Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Remove the power steering inlet hose (2) from the power steering pump (1). 2. Remove the power steering inlet hose (2) from the power steering gear (3). Installation Procedure 1. Connect the power steering inlet hose (2) to the power steering gear (3). 2. Notice: Refer to Fastener Notice in Service Precautions. Connect the power steering inlet hose (2) to the power steering pump (1). ^ Tighten the hose connections to 28 Nm (20 ft. lbs.). 3. Bleed the power steering system. Refer to Bleeding the Power Steering System. 4. Inspect all the hose connections for leaks. (With Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (With Hydroboost) Removal Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 2379 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the power steering gear inlet hose (1) from the brake booster. 3. Remove the power steering gear inlet hose from the power steering gear. 4. Remove the power steering gear inlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear inlet hose (1) to the brake booster (2). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear inlet hose to the power steering gear. ^ Tighten both power steering gear inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. (Without Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Without Hydroboost) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine protection shield. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 2380 3. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 4. Remove the power steering gear inlet hose (3) from the power steering pump (1). 5. Remove the power steering gear inlet hose from the power steering gear. 6. Remove the power steering gear inlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear inlet hose (3) to the power steering pump (1). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear inlet hose to the power steering gear. ^ Tighten both power steering gear inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Install the engine protection shield. 6. Lower the vehicle. 7. Bleed the power steering system. Refer to Bleeding the Power Steering System. (Recirculating Ball) Power Steering Gear Outlet Pipe/Hose Replacement (Recirculating Ball) Removal Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 2381 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the power steering gear outlet hose (3) from the steering gear (2). 3. Remove the clamp retaining the power steering gear outlet hose (3) to the power steering pump (1).Remove the power steering gear outlet hose from the power steering pump. 4. Remove the power steering gear outlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear outlet hose (3) to the power steering pump (1).Position the clamp at the end of the hose. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear outlet hose to the power steering gear. ^ Tighten the outlet hose fitting to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. (Rack and Pinion) Power Steering Gear Outlet Pipe/Hose Replacement (Rack and Pinion) Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 2382 1. Remove the power steering outlet hose (4) from the power steering gear (3). 2. Remove the power steering outlet hose (4) from the power steering cooler (5). Installation Procedure 1. Connect the power steering outlet hose (4) to the power steering cooler (5). 2. Connect the power steering outlet hose (4) to the power steering gear (3). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Connect the power steering outlet hose (2) to the power steering pump (1). ^ Tighten both hose connections to 28 Nm (20 ft. lbs.). 4. Bleed the power steering system. Refer to Bleeding the Power Steering System. 5. Inspect all the hose connections for leaks. Power Brake Booster Inlet Hose Replacement Power Brake Booster Inlet Hose Replacement Removal Procedure 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 2383 2. Remove the brake booster inlet hose (1) from the brake booster (2). 3. Remove the brake booster inlet hose from the power steering pump. 4. Remove the brake booster inlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the brake booster inlet hose (1) to the brake booster (2). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the brake booster inlet hose to the power steering pump. ^ Tighten the brake booster inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. Power Brake Booster Outlet Hose Replacement Power Brake Booster Outlet Hose Replacement Removal Procedure 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the brake booster outlet hose (1) from the brake booster (2). 3. Remove the clamp retaining the brake booster outlet hose to the power steering pump. 4. Remove the brake booster outlet hose from the vehicle. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 2384 1. Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. Route the hose in the same position the hose occupied prior to removal. 2. Install the brake booster outlet hose (1) to the brake booster (2).Position the clamp at the end of the hose. 3. Install the brake booster outlet hose to the power steering pump (4).Position the clamp at the end of the hose. 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. (Non Rack and Pinion) Power Steering Hose Assembly Replacement (Non Rack and Pinion) Removal Procedure 1. Disconnect the energy storage box before serving the vehicle. 2. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Remove the power steering gear inlet hose (4) from the brake booster. 4. Remove the power brake booster outlet hose (3) retaining clamp (2) to remove the power brake booster hose outlet hose from the brake booster. 5. Remove the power brake booster inlet hose (1) from the brake booster. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 2385 6. Remove the power steering gear inlet hose (4) from the power steering gear. 7. Remove the power brake booster outlet hose (2) retaining clamp (3) to remove the power brake booster outlet hose from the power steering pump. 8. Remove the power brake booster inlet hose from the power steering pump. 9. Remove the power steering hose assembly from the vehicle. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 2386 1. Install the gear inlet hose to the gear (4). Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Important: Following this sequence ensures correct routing and orientation. 2. Install the booster inlet hose to the pump. Important: Ensure that the hose contacts the power steering pump as shown. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 2387 3. Install the booster outlet hose to the power steering pump nipple (5) and retaining clamp. 4. Install the booster inlet hose (1) to the booster. 5. Install the gear inlet hose to the booster. ^ Tighten both power steering inlet hose fittings to 32 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the booster outlet hose (3) to the booster and install the retaining clamp (2). 7. Remove the drain pan from under the vehicle. 8. Bleed the power steering system. Refer to Bleeding the Power Steering System. 9. Connect the energy storage box after servicing the vehicle. (Rack and Pinion) Power Steering Hose Assembly Replacement (Rack and Pinion) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 2388 Removal Procedure 1. Disconnect the energy storage box before servicing the vehicle. 2. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Remove the power steering gear inlet hose (4) from the brake booster. 4. Remove the power brake booster outlet hose (3) retaining clamp (2) to remove the power brake booster hose outlet hose from the brake booster. 5. Remove the power brake booster inlet hose (1) from the brake booster. 6. Remove the power steering gear inlet hose (5) from the power steering gear. 7. Remove the power brake booster outlet hose (2) retaining clamp (3) to remove the power brake booster outlet hose from the power steering pump. 8. Remove the power brake booster inlet hose (5) from the power steering pump. 9. Remove the power steering hose assembly from the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 2389 Installation Procedure 1. Install the booster inlet hose to the pump. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Important: Following this sequence ensures correct routing and orientation. Important: Ensure that the hose contacts the power steering pump as shown. 2. Install the gear inlet hose to the gear (5). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 2390 3. Install the booster outlet hose to the power steering pump nipple and retaining clamp (2). 4. Install the booster inlet hose (1) to the booster. 5. Install the gear inlet hose to the booster. ^ Tighten both power steering inlet hose fittings to 32 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the booster outlet hose (3) to the booster and install the retaining clamp (2). 7. Remove the drain pan from under the vehicle. 8. Bleed the power steering system. Refer to Bleeding the Power Steering System. 9. Connect the energy storage box before after servicing the vehicle. (Rack and Pinion) Power Steering Cooler Pipe/Hose Replacement (Rack and Pinion) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 2391 Removal Procedure 1. Remove the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. 2. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Remove the power steering outlet hose (4) from the power steering gear (3). 3. Remove the power steering inlet hose from the power steering pump (1). 4. Remove the bolts (2) retaining the cooler to the radiator support. 5. Remove the power steering cooler from the vehicle. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering cooler (1) to the vehicle. ^ Tighten the power steering cooler retaining bolts to 5 Nm (44 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 2392 2. Connect the power steering inlet hose to the power steering pump (5).Install the retaining clamp. 3. Connect the power steering outlet hose (4) to the power steering gear (3).Install the retaining clamp. 4. Bleed the power steering system. Refer to Bleeding the Power Steering System. 5. Inspect all the hose connections for leaks. 6. Install the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. (With Hydroboost) Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) Removal Procedure 1. Remove the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. 2. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Place a drain pan under the vehicle. 3. Siphon the fluid from the reservoir to prevent excess spillage. 4. Remove the clamp retaining the power steering cooler inlet hose (3) to the power steering gear (2). 5. Remove the clamp retaining power steering cooler outlet hose (5) to the power steering pump (1). 6. Remove the bolts (2) retaining the power steering cooler from the radiator support. 7. Remove the power steering cooler from the vehicle. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 2393 1. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering cooler (1) to the radiator support. ^ Tighten the bolts retaining the power steering cooler to 5 Nm (44 inch lbs.). 2. Install the power steering cooler outlet hose (3) to the power steering pump (2). 3. Install the retaining clamp. 4. Install the power steering inlet hose (5) to the power steering gear (1). 5. Install the retaining clamp. 6. Fill and bleed the power steering system. Refer to Bleeding the Power Steering System. 7. Inspect all the hose connections for leaks. 8. Install the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. (Without Hydroboost) Power Steering Cooler Pipe/Hose Replacement (Without Hydroboost) Removal Procedure 1. Remove the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. 2. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Remove the clamp retaining the power steering outlet hose (3) from the power steering gear (4). 3. Remove the clamp retaining the power steering inlet hose from the power steering pump (5). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 2394 4. Remove the bolts (2) retaining the power steering cooler from the radiator support. 5. Remove the power steering cooler from the vehicle. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering cooler (1) to the vehicle. ^ Tighten the power steering cooler retaining bolts to 5 Nm (44 inch lbs.). 2. Connect the power steering outlet hose (3) to the power steering gear (4). 3. Install the retaining clamp. 4. Connect the power steering inlet hose to the power steering pump. 5. Install the retaining clamp. 6. Bleed the power steering system. Refer to Bleeding the Power Steering System. 7. Inspect all the hose connections for leaks. 8. Install the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. (Parallel Hybrid Truck) Power Steering Cooler Pipe/Hose Replacement (Parallel Hybrid Truck) Removal Procedure 1. Disconnect the energy storage box before servicing the vehicle. 2. Remove the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 2395 3. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Place a drain pan under the vehicle. 4. Siphon the fluid from the reservoir to prevent excess spillage. 5. Remove the clamp retaining the power steering cooler inlet hose (3) to the power steering gear. 6. Remove the clamp retaining power steering cooler outlet hose (2) to the power steering pump (1). 7. Remove the bolts (2) retaining the power steering cooler from the radiator support. 8. Remove the power steering cooler from the vehicle. Installation Procedure 1. Notice: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 2396 Refer to Fastener Notice in Service Precautions. Install the power steering cooler (1) to the radiator support. ^ Tighten the bolts retaining the power steering cooler to 5 Nm (44 inch lbs.). 2. Install the power steering cooler outlet hose (2) to the power steering pump (1). 3. Install the retaining clamp. 4. Install the power steering inlet hose (3) to the power steering gear (1). 5. Install the retaining clamp. 6. Fill and bleed the power steering system. Refer to Bleeding the Power Steering System. 7. Inspect all the hose connections for leaks. 8. Install the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. 9. Connect the energy storage box after servicing the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Inlet Radiator Hose: Service and Repair Inlet Radiator Hose Replacement - Inlet (6.6L Engine) Removal Procedure 1. Drain the engine coolant. 2. Move the hose clamps back on the radiator inlet hose. 3. Remove the radiator inlet hose from the radiator. 4. Remove the radiator inlet hose from the water outlet tube. Installation Procedure 1. Install the radiator inlet hose to the water outlet tube. 2. Install the radiator inlet hose to the radiator. 3. Install the hose clamps on the radiator outlet hose. 4. Fill the engine coolant. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Inlet > Page 2401 Radiator Hose: Service and Repair Outlet Radiator Hose Replacement - Outlet (6.6L Engine) Removal Procedure 1. Drain the engine coolant. 2. Remove the upper and lower fan shroud. 3. Remove the surge tank outlet hose (2) from the surge tank. 4. Remove the radiator outlet hose from the water pump. 5. Remove the heater outlet hose from the radiator outlet hose. 6. Remove the radiator outlet hose from the radiator. 7. Remove the radiator outlet hose clip retainers from the brackets. 8. Remove the radiator outlet hose from the vehicle. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Inlet > Page 2402 1. Install the radiator outlet hose to the vehicle. 2. Install the radiator outlet hose and clamp to the radiator. Ensure the hose is positioned properly in order to prevent interference with the fan shroud. 3. Install the radiator outlet hose clip retainers to the brackets. 4. Install the surge tank outlet hose (2) to the surge tank. 5. Install the radiator outlet hose and clamp to the water pump. 6. Install the heater outlet hose to the radiator outlet hose. 7. Install the upper and lower fan shroud. 8. Fill the engine coolant. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Inlet > Page 2403 Radiator Hose: Service and Repair Radiator Vent Inlet Hose Replacement Radiator Vent Inlet Hose Replacement Removal Procedure 1. Drain the cooling system. 2. Reposition the vent inlet hose clamp from the radiator. 3. Remove the vent inlet hose from the radiator. 4. Reposition the vent inlet hose clamp from the surge tank. 5. Remove the vent inlet hose from the surge tank. Installation Procedure 1. Install the vent inlet hose to the surge tank. 2. Reposition the vent inlet hose clamp to the surge tank. 3. Install the vent inlet hose to the radiator. 4. Reposition the vent inlet hose clamp to the radiator. 5. Fill the cooling system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Inlet > Page 2404 Radiator Hose: Service and Repair Radiator Hose Quick Connect Fitting Radiator Hose Quick Connect Fitting Removal Procedure 1. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring. 2. Rotate the retaining ring (3) around the quick connector until the retaining ring is out of position and can be completely removed. 3. Remove the radiator outlet hose (2) from the quick connector fitting at the radiator (1). Installation Procedure 1. Important: Do not install the retaining ring (3) onto the fitting by pushing the retaining ring down over the fitting. Hook one of the open ends of the retaining ring (3) in one of the slots in the quick connector. 2. Rotate the retaining ring (3) around the connector until the retaining ring is positioned with all 3 ears through the 3 slots. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Inlet > Page 2405 3. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots. 4. Install the radiator outlet hose (2) onto the radiator quick connector fitting until a click is heard or felt.Pull back on the radiator outlet hose (2) to ensure a proper connection. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Capacity Specifications Brake Fluid: Capacity Specifications Information not supplied by the manufacturer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Capacity Specifications > Page 2411 Brake Fluid: Fluid Type Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme II Brake Fluid or equivalent DOT-3 brake fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications HYDRAULIC CLUTCH FLUID 5-SPEED TRANS. Hydraulic Clutch Fluid (GM Part No. U.S. 12345347, in Canada 10953517) or equivalent DOT-3 brake fluid. 6-SPEED TRANS. Hydraulic Clutch Fluid. Use only GM Part No. U.S. 88958860, in Canada 88901244, DOT-4 brake fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2419 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2420 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2421 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2422 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System ................................................................................................................................... ............................................... 23.0 liters (24.0 quarts) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 2425 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs first, if you add only DEX-COOL extended life coolant. A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will: ^ Give freezing protection down to -34°F (-37°C). ^ Give boiling protection up to 265°F (129°C). ^ Protect against rust and corrosion. ^ Help keep the proper engine temperature. ^ Let the warning lights and gages work as they should. NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle. WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't damage aluminum parts. If you use this coolant mixture, you don't need to add anything else. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. If you have to add coolant more than four times a year, check your cooling system. NOTICE: If you use the proper coolant, you do not have to add extra inhibitors or additives which claim to improve the system. These can be harmful. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Fluid - A/T: Customer Interest Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2434 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2435 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2436 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2437 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2438 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2439 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2440 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 04-07-30-037E > Apr > 11 > A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: All Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 04-07-30-037E > Apr > 11 > A/T - DEXRON(R)-VI Fluid Information > Page 2446 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 08-07-30-035B > Nov > 10 > A/T - Water Or Coolant Contamination Information Fluid - A/T: All Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 08-07-30-035B > Nov > 10 > A/T - Water Or Coolant Contamination Information > Page 2451 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Fluid - A/T: All Technical Service Bulletins Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2456 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2457 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2458 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2459 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2460 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2461 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2462 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 05-00-90-005 > May > 05 > A/T - Allison, Service Interval/Filter Change Correction Fluid - A/T: All Technical Service Bulletins A/T - Allison, Service Interval/Filter Change Correction Bulletin No.: 05-00-90-005 Date: May 26, 2005 SERVICE MANUAL UPDATE Subject: Revised Maintenance and Lubrication for Automatic Transmission Service Interval/Correct Filter to Replace Models: 2001-2006 Chevrolet Silverado 2001-2006 GMC Sierra with Allison(R) Automatic Transmission This bulletin is being issued to revise the first automatic transmission service interval and specify what filter to replace in the Maintenance and Lubrication sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI for 2001-2004. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The 2005 and 2006 Owner's Manuals have also been corrected. The first automatic transmission service interval is at the first maintenance service performed on the vehicle. At that time, change the external spin-on filter only. At every 83,000 km (50,000 miles) (normal service) or every 41,500 km (25,000 miles) (severe service), change the external spin-on filter and fluid. The sump filter is to be changed only during an overhaul. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 04-07-30-037E > Apr > 11 > A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: All Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 04-07-30-037E > Apr > 11 > A/T - DEXRON(R)-VI Fluid Information > Page 2472 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 08-07-30-035B > Nov > 10 > A/T - Water Or Coolant Contamination Information Fluid - A/T: All Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 08-07-30-035B > Nov > 10 > A/T - Water Or Coolant Contamination Information > Page 2477 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 05-00-90-005 > May > 05 > A/T - Allison, Service Interval/Filter Change Correction Fluid - A/T: All Technical Service Bulletins A/T - Allison, Service Interval/Filter Change Correction Bulletin No.: 05-00-90-005 Date: May 26, 2005 SERVICE MANUAL UPDATE Subject: Revised Maintenance and Lubrication for Automatic Transmission Service Interval/Correct Filter to Replace Models: 2001-2006 Chevrolet Silverado 2001-2006 GMC Sierra with Allison(R) Automatic Transmission This bulletin is being issued to revise the first automatic transmission service interval and specify what filter to replace in the Maintenance and Lubrication sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI for 2001-2004. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The 2005 and 2006 Owner's Manuals have also been corrected. The first automatic transmission service interval is at the first maintenance service performed on the vehicle. At that time, change the external spin-on filter only. At every 83,000 km (50,000 miles) (normal service) or every 41,500 km (25,000 miles) (severe service), change the external spin-on filter and fluid. The sump filter is to be changed only during an overhaul. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 4L60-E Pan Removal ........................................................................................... .......................................................................................................... 4.7L (5.0 Qt) Overhaul .............. .............................................................................................................................................................. ............................ 10.6L (11.0 Qt) 4L80-E Overhaul ........................................................................... ............................................................................................................................. 12.8L (13.5 Qt) Pan Removal .............................................................................................................................................. ....................................................... 7.3L (7.7 Qt) Allison Overhaul ..................................................... ................................................................................................................................................... 12.0L (12.7 Qt) Fluid and Filter Change ........................................................................................................ ............................................................................. 7.0L (7.4 Qt) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 2484 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 2485 Fluid - A/T: Service and Repair Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. Allow the transmission fluid to drain completely. 5. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the treads of the drain plug, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 7. Remove the drain pan from under the transmission oil pan. 8. Support the transmission with a transmission jack. 9. Remove the transmission mount nuts. 10. Remove the transmission support bolts and nuts. 11. Remove the transmission support side bracket bolts and bracket. 12. Remove the transmission support. 13. Disconnect the range selector cable end (2) from the transmission range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 2486 14. Important: It is not necessary to remove the selector cable from the bracket. Remove the transmission range selector cable bracket (2) bolts and bracket from the transmission. Reposition the bracket with cable. 15. Remove the oil pan bolts. 16. Important: The transmission oil pan gasket is reusable. Inspect the gasket and replace as needed. Remove the oil pan and gasket. 17. Remove the magnet from the bottom of the pan, if necessary. 18. Remove the oil filter. 19. Remove the filter neck seal. 20. Clean the transmission case and the oil pan gasket surfaces with solvent. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 2487 1. Install the filter neck seal. 2. Install the oil filter. 3. Install the oil pan gasket to the pan. 4. Install the magnet into the bottom of the pan, if necessary. 5. Install the oil pan and bolts. ^ Tighten the oil pan bolts to 24 Nm (18 ft. lbs.). 6. Position the bracket with cable. Install the transmission range selector cable bracket (2) and bolts to the transmission. ^ Tighten the selector bracket bolts to 25 Nm (18 ft. lbs.). 7. Connect the range selector cable end (2) to the transmission range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 2488 8. Install the transmission support. 9. Install the transmission support side bracket and bolts. 10. Install the transmission support bolts and nuts. ^ Tighten the bolts/nuts to 95 Nm (70 ft. lbs.). 11. Install the transmission mount nuts. ^ Tighten the nuts to 40 Nm (30 ft. lbs.). 12. Remove the transmission jack. 13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON® III transmission fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid - M/T: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Fluid - M/T: Customer Interest Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid - M/T: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2497 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid - M/T: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2498 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid - M/T: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2499 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid - M/T: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2500 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid - M/T: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2501 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid - M/T: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2502 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid - M/T: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2503 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - M/T: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Fluid - M/T: All Technical Service Bulletins Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - M/T: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2509 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - M/T: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2510 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - M/T: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2511 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - M/T: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2512 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - M/T: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2513 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - M/T: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2514 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - M/T: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 2515 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Transmission Fluid NV3500 ................................................................................................................ ............................................................................................. 2.3L (2.4 Qt) NV4500 ............................ .............................................................................................................................................................. ................... 3.8L (4.0 Qt) 6 Speed (ZF) (RPO ML6) ........................................................................... ...................................................................................................... 6.0L (6.3 Qt) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 2518 Fluid - M/T: Fluid Type Specifications Transmission Fluid 5-SPEED WITH LOW GEAR (RPO MW3) Grade ............................................................................... .............................................................................................................................. GL-4 Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 5-SPEED WITHOUT LOW GEAR (RPO MG5) Fluid Type ................................................................................................................................................. Synchromesh Transmission Fluid P/N 12345349 6-SPEED Fluid Type ....................................................................................................................... Synthetic Transmission Fluid approved for Allison Transmission Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > NV 3500 Fluid - M/T: Service and Repair NV 3500 Transmission Fluid Replacement ^ Tools Required J 36511 Oil Fill/Drain Plug Hex Bit (17 MM) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Using J 36511 remove the oil fill plug. 3. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 4. Using J 36511 remove the oil drain plug. 5. Remove any old sealant from the transmission housing. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > NV 3500 > Page 2521 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil drain and fill plug threads. 2. Notice: Refer to Fastener Notice in Service Precautions. Using J 36511 install the oil drain plug. ^ Tighten the plug to 30 Nm (22 ft. lbs.). 3. Remove and drain the drain pan used to catch the used transmission fluid. 4. Fill the transmission to just below the bottom of the fill plug hole. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > NV 3500 > Page 2522 5. Using J 36511 install the oil fill plug. ^ Tighten the plug to 30 Nm (22 ft. lbs.). 6. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > NV 3500 > Page 2523 Fluid - M/T: Service and Repair NV 4500 Transmission Fluid Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the oil fill plug. 3. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 4. Remove the oil drain plug. 5. Remove any old sealant from the transmission housing. Installation Procedure 1. Apply a thin bead of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil drain and fill plug threads. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil drain plug. ^ Tighten the plug to 37 Nm (27 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > NV 3500 > Page 2524 3. Fill the transmission to just below the bottom of the fill plug hole. 4. Install the oil fill plug. ^ Tighten the plug to 37 Nm (27 ft. lbs.). 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > NV 3500 > Page 2525 Fluid - M/T: Service and Repair ZF S6-650 Transmission Fluid Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the oil fill plug. 3. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 4. Remove the oil drain plug. 5. Remove any old sealant from the transmission housing and plugs. Installation Procedure 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the treads of the oil drain and fill plugs. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil drain plug. ^ Tighten the plug to 35 Nm (26 ft. lbs.). 3. Fill the transmission to just below the bottom of the fill plug hole. Refer to Lubrication Specifications. 4. Install the oil fill plug. ^ Tighten the plug to 35 Nm (26 ft. lbs.). 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Front Drive Axle Lubrication Update Fluid - Differential: Technical Service Bulletins Drivetrain - Front Drive Axle Lubrication Update Bulletin No.: 05-00-90-010 Date: December 07, 2005 SERVICE MANUAL UPDATE Subject: Revised Front Drive Axle Carrier Lubricant Information Models: 1999-2005 Light Duty Trucks 2003-2005 HUMMER H2 2005 Saab 9-7X with Four-Wheel or All-Wheel Drive and Separate Front Drive Axle Carriers This bulletin is being issued to revise the front drive axle carrier lubricant specification in the Maintenance and Lubrication and the Front Drive Axle sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. This information also updates the information found in the Owner Manual. Important: Front drive axle carriers do not require periodic lubricant replacement. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Front Drive Axle Lubrication Update > Page 2530 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Front Drive Axle Lubrication Update > Page 2531 Fluid - Differential: Technical Service Bulletins Drivetrain - Synthetic Fluid Usage in Front Differential File In Section: 04 - Driveline Axle Bulletin No.: 03-04-19-001B Date: September, 2004 INFORMATION Subject: Use of Synthetic Front Axle Lubricant for 4WD Vehicles Sold in Cold Weather Climates Models: 2002-2004 Chevrolet Avalanche 2500, Silverado 2500/3500, Suburban 2500 2002-2003 Chevrolet Silverado 1500HD 2002-2004 GMC Sierra 2500/3500, Yukon XL 2500 2002-2003 GMC Sierra 1500HD with Four-Wheel Drive and 9.25" Front Axle Assemblies and Built Prior to April 1, 2004 This bulletin is being revised to update vehicle applications, part numbers and fluid fill information. Please discard Corporate Bulletin Number 03-04-19-001A (Section 04 - Driveline/Axle). Important: This bulletin is intended for vehicles sold in very cold weather climates, especially those in Alaska and certain regions of Canada. Important: This bulletin DOES NOT apply to vehicles built after April 1, 2004. Vehicles referenced above that were built after April 1, 2004 were manufactured with front axles containing synthetic axle lubricant and do not need to have the front axle fluid inspected or changed. Front axles in the above-listed vehicles built before April 1, 2004 are manufactured with mineral-oil base axle fluid. Because of the 9.25" front axle assembly's internal design characteristics, there may be insufficient lubrication flow at very low ambient temperatures (-24°C (-12°F) or below). This may contribute to premature pinion bearing wear if a vehicle is driven extensively in very low ambient temperatures. Important: Please be certain that PDI personnel know to perform the drain/refill procedure all year round (not just in the cold weather months). New vehicles that are expected to operate extensively in 4WD in temperatures below -24°C (-12°F) should have their front axle fluid drained and refilled with synthetic axle lubricant during PDI or before delivery to the first retail customer. Follow the Front Drive Axle Lubricant Replacement procedure found in the Service Manual. It is not necessary to flush the front axle assembly. Use Synthetic Axle Lubricant, P/N 12378261 or P/N 89021677 (Canadian P/N 10953455 or P/N 89021678). Each of these part numbers is the same axle lubricant, with differences in packaging only. Fill to a level between 6 and 9 mm (0.25 in to 0.375 in) below the bottom of the fill plug. For vehicles that have the axle lubricant changed, the front axle vent hose connector assembly will need to be inspected. Important: Front axle assemblies with a vent hose connector assembly that is white in color do not need to be changed. If the vent hose connector is black in color, it will need to be changed so that the 0-ring seal is compatible with the synthetic lubricant Install vent connector, P/N 12479390. Follow the Front Drive Axle Vent Hose Connector Replacement procedure in the Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Front Drive Axle Lubrication Update > Page 2532 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Fluid Capacity Differential Oil Capacity Front Drive Axle (8.25") ....................................................................................................................... ............................................ 1.43 liters (1.51 quarts) Front Drive Axle (9.25") .................................... ............................................................................................................................... 1.73 liters (1.83 quarts) Rear Drive Axle (8.6") ............................................................................................................. ......................................................... 2.03 liters (2.15 quarts) Rear Drive Axle (9.5") .......................... ............................................................................................................................................ 2.60 liters (2.75 quarts) Rear Drive Axle (9.75") .................................................................................................. .................................................................. 2.84 liters (3.00 quarts) Rear Drive Axle (10.5") ............... ..................................................................................................................................................... 2.60 liters (2.75 quarts) Rear Drive Axle (11.5") .......................................................................................... .......................................................................... 3.00 liters (3.17 quarts) Lubricant Level - 8.6 Inch Axle Differential Oil Capacity Capacity .................................................................................................................................................... 15-40 mm from bottom edge of the fill plug hole Lubricant Level - 9.5, 10.5 Inch Axles Differential Oil Capacity Capacity ............................................................................................................................................... ........................ 0-10 mm below the fill plug opening Lubricant Level - 9.75 Inch Axel Differential Oil Capacity Capacity ............................................................................................................................................... .......................... 0-4 mm below the fill plug opening Lubricant Level - 11.5 Inch Axle Differential Oil Capacity Capacity ............................................................................................................................................... ...................... 17-21 mm below the fill plug opening Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 2535 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Differential Fluid Type Front 4WD Grade ................................................................................................................................ ............................................................................................. GL-5 Viscosity ....................................... .............................................................................................................................................................. .............. 80W-90 Front AWD Grade ................................................................................................... .................................................................................................................... Synthetic Viscosity .......... .............................................................................................................................................................. ........................................... 75W-90 Rear Grade ................................................................................ ....................................................................................................................................... Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 Rear (Steerable) Grade ................................... .............................................................................................................................................................. ...................... Synthetic Viscosity ........................................................................................................ ........................................................................................................... 75W-90 Front Differential Differential Fluid Type The content of this article reflects the changes identified in TSB number 05-00-90-010 dated December 07, 2005. 1999-2004 7.25 Inch (Blazer, Jimmy, S-10, Sonoma, Astro, Safari) Grade ........................................ .............................................................................................................................................................. ....................... GL-5 Viscosity ............................................................................................................. ...................................................................................................... 80W-90 2002-2005 7.25 Inch (Trailblazer, Envoy, Bravada, Rainier Grade ....................................................................................... ................................................................................................................................ Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 8.25 Inch With Selectable 4WD Grade ............ .............................................................................................................................................................. ................................................... GL-5 Viscosity ................................................................................. .................................................................................................................................. 80W-90 8.25 Inch With AWD Grade ......................................................................................................................... .............................................................................................. Synthetic Viscosity ................................ .............................................................................................................................................................. ..................... 75W-90 1999-2001 9.25 Inch Grade ............................................................................. ................................................................................................................................................ GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 2002-2005 9.25 Inch Grade ............................. .............................................................................................................................................................. ............................ Synthetic Viscosity .................................................................................................. ................................................................................................................. 75W-90 Front Drive Axle Differential Fluid Type The content of this article reflects the changes identified in TSB number 05-00-90-010 dated December 07, 2005. 1999-2004 7.25 Inch (Blazer, Jimmy, S-10, Sonoma, Astro, Safari) Grade ........................................ .............................................................................................................................................................. ....................... GL-5 Viscosity ............................................................................................................. ...................................................................................................... 80W-90 2002-2005 7.25 Inch (Trailblazer, Envoy, Bravada, Rainier Grade ....................................................................................... ................................................................................................................................ Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 8.25 Inch With Selectable 4WD Grade ............ .............................................................................................................................................................. ................................................... GL-5 Viscosity ................................................................................. .................................................................................................................................. 80W-90 8.25 Inch With AWD Grade ......................................................................................................................... .............................................................................................. Synthetic Viscosity ................................ .............................................................................................................................................................. ..................... 75W-90 1999-2001 9.25 Inch Grade ............................................................................. ................................................................................................................................................ GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 2002-2005 9.25 Inch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 2536 Grade ................................................................................................................................................... .................................................................... Synthetic Viscosity .......................................................... ......................................................................................................................................................... 75W-90 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle Fluid - Differential: Service and Repair Front Drive Axle Lubricant Level Inspection Lubricant Level Inspection - Front Drive Axle 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the front axle for leaks. Repair as necessary. 4. Clean the area around the front axle fill plug. 5. Remove the front axle fill plug (1). 6. Inspect the oil level. ^ For the 8.25 inch axle, the oil level should be between 12-16 mm (0.50-0.625 inch) below the fill plug opening. ^ For the 9.25 inch axle, the oil level should be between 0-6 mm (0-0.25 inch) below the fill plug opening. 7. If the level is low, add oil until the level is between 12-16 mm (0.50-0.625 inch) for the 8.25 inch axle or 0-6 mm (0-0.25 inch) for the 9.25 inch axle. Use the correct fluid. 8. Install the fill plug. ^ Tighten the plug to 33 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 9. Lower the vehicle. Lubricant Replacement Lubricant Replacement - Front Drive Axle Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the front differential carrier shield, if equipped. 3. Clean the area around the front axle fill plug and the drain plug. 4. Remove the fill plug. 5. Remove the drain plug. 6. Drain the fluid from the front differential carrier assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle > Page 2539 Installation Procedure 1. Install the drain plug. ^ Tighten the drain plug to 33 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Fill the differential carrier assembly with axle lubricant. Use the correct fluid. 3. Install the fill plug. ^ Tighten the fill plug to 33 Nm (24 ft. lbs.). 4. Install the front differential carrier shield, if equipped. 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle > Page 2540 Fluid - Differential: Service and Repair Rear Drive Axle 8.6 Inch Axle Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Fabricate a dipstick from a pipe cleaner or similar item. Form the pipe cleaner into an "L". 7. Insert the pipe cleaner into the fill plug opening with the stem facing down. 8. Remove the pipe cleaner and measure the distance from the bend in the pipe cleaner to the lubricant level. The distance between the bend and the lubricant level should be 15-40 mm (0.6-1.6 inch). 9. If the measurement is greater than 40 mm (1.6 inch), add lubricant until the level is between 15-40 mm (0.6-1.6 inch) from the bottom edge of the fill plug hole. Use the proper fluid. 10. Notice: Refer to Fastener Notice in Service Precautions. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 11. Lower the vehicle. 9.5, 10.5 Inch Axle Lubricant Level Inspection - Rear Drive Axle (9.5, 10.5 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting in General Information. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0-10 mm (0-0.4 inch) below the fill plug opening. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle > Page 2541 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. 8. Notice: Refer to Fastener Notice in Service Precautions. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 9. Lower the vehicle. 9.75 Inch Axle Lubricant Level Inspection - Rear Drive Axle (9.75 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Ensure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0-4 mm (0-0.16 inch) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. 8. Notice: Refer to Fastener Notice in Service Precautions. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 21 Nm (15 ft. lbs.). 9. Lower the vehicle. 11.5 Inch Axle Lubricant Level Inspection - Rear Drive Axle (11.5 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug and the seal. 6. Inspect the lubricant level. The lubricant level should be between 17-21 mm (0.6-0.8 inch) below the fill plug opening. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle > Page 2542 7. If the level is low, add lubricant until the level is between 17-21 mm (0.6-0.8 inch) below the fill plug opening. Use the proper fluid. 8. Notice: Refer to Fastener Notice in Service Precautions. Install the rear axle fill plug and gasket. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 9. Lower the vehicle. 8.6 Inch Axle Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the rear axle fill plug. 3. Remove the rear axle housing cover bolts (1). Discard the rear axle housing cover bolts. 4. Carefully remove the rear axle housing cover (2) and drain the lubricant into a suitable container. 5. Remove any gasket material from the rear axle housing and/or the rear axle housing cover. 6. Inspect the bottom of the rear axle housing for excessive metal particle accumulation. This accumulation is an indication of extreme wear. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle > Page 2543 1. Install a new gasket and the rear axle housing cover (2). 2. Notice: Refer to Fastener Notice in Service Precautions. Important: Do not reuse the rear axle housing cover bolts. Install the new rear axle housing cover bolts (1). ^ Tighten the bolts to 40 Nm (30 ft. lbs.). 3. Fill the rear axle. Use the proper fluid. 4. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 5. Lower the vehicle. 9.75 Inch Axle Lubricant Replacement - Rear Drive Axle (9.75 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the rear axle fill plug. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle > Page 2544 3. Remove the rear axle drain plug. 4. Drain the lubricant into a suitable container. 5. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 6. Clean the drain plug. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the rear axle drain plug. ^ Tighten the rear axle drain plug to 27 Nm (20 ft. lbs.). 2. Fill the rear axle. Use the proper fluid. 3. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 21 Nm (15 ft. lbs.). 4. Lower the vehicle. 9.5, 10.5, and 11.5 Inch Axles Lubricant Replacement - Rear Drive Axle (9.5, 10.5, and 11.5 Inch Axles) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle > Page 2545 2. For the 9.5 inch and the 10.5 inch axles, remove the rear axle fill plug. 3. For the 11.5 inch axle, remove the fill plug. 4. Remove the rear axle drain plug. 5. Drain the lubricant into a suitable container. 6. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 7. Clean the drain plug. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the rear axle drain plug. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle > Page 2546 ^ Tighten the rear axle drain plug to 33 Nm (24 ft. lbs.). 2. Fill the rear axle. Use the proper fluid. 3. For the 9.5 inch and the 10.5 inch axles, install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 4. For the 11.5 inch axle, install the seal and the fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case NVG 246 (RPO NP8) ........................................................................................................................... ........................................................... Not Specified NVG 261 (RPO NP2) ........................................ .............................................................................................................................................. Not Specified NVG 263 (RPO NPI) ............................................................................................................ ........................................................................... 1.9L (2.0 QT) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 2551 Fluid - Transfer Case: Fluid Type Specifications NVG 149-NP3 ................................................................................................... Manual Transmission Fliod GM P/N 8861800 (Canadian P/N 88861801) NVG 246-NP8 ......................................................................................... Auto-Trak II, transfer case fluid, GM P/N 12378508 (Canadian P/N 10953626) NVG 261-NP2 ................................................................................................... Manual Transmission Fliod GM P/N 8861800 (Canadian P/N 88861801) NVG 263-NP1 ................................................................................................... Manual Transmission Fliod GM P/N 8861800 (Canadian P/N 88861801) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 Fluid - Transfer Case: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Fluid Replacement Removal Procedure Important: When performing the following procedure, use only hand tools to remove and install the drain and fill plugs. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield, if equipped. 3. Remove the fill plug. 4. Remove the drain plug. Important: Ensure that an approved drain pan is used when draining the transfer case. 5. Allow the transfer case to drain completely. Installation Procedure 1. Install the drain plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Important: Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 2554 2. Fill the transfer case to the bottom of the fill plug hole with DEXRON® III, GM P/N 12346143 (Canadian P/N 10952622). 3. Install the fill plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 4. Install the transfer case shield, if equipped. 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 2555 Fluid - Transfer Case: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Fluid Replacement Removal Procedure Important: When performing the following procedures, use only hand tools to remove and install the drain and fill plugs. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield, if equipped. 3. Remove the fill plug. 4. Remove the drain plug. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Important: Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case. Install the drain plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 2. Fill the transfer case to the bottom of the fill plug hole with Auto-Trak II, transfer case fluid, GM P/N 12378508 (Canadian P/N 10953626). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 2556 3. Install the fill plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 4. Install the transfer case shield, if equipped. 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 2557 Fluid - Transfer Case: Service and Repair Transfer Case - NVG 261-NP2 Transfer Case Fluid Replacement Removal Procedure Important: When performing the following service procedures, use only hand tools in order to remove and install the fill or drain plugs. Always start the plugs by hand in order to prevent cross threading. 1. Remove the transfer case shield, if equipped. 2. Remove the fill plug. 3. Remove the drain plug. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: If the drain or fill plug have to be replaced, use only aluminum replacement drain plugs. Steel plugs will react with the magnesium of the transfer case. 1. Install the drain plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 2. Fill the transfer case to the bottom of the fill plug hole with the approved transfer case fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 2558 3. Install the fill plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 4. Install the transfer case shield, if equipped. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 2559 Fluid - Transfer Case: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Fluid Replacement Removal Procedure Important: When performing the following procedure, use only hand tools to remove and install the drain and fill plugs. 1. Remove the transfer case shield, if equipped. 2. Remove the fill plug. 3. Remove the drain plug. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case. 1. Install the drain plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 2. Fill the transfer case to the bottom of the fill plug hole with the approved fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 2560 3. Install the fill plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 4. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Diesel Engine - Greater Than Expected Oil Consumption Engine Oil: Technical Service Bulletins Diesel Engine - Greater Than Expected Oil Consumption Bulletin No.: 02-06-01-027A Date: May 17, 2005 INFORMATION Subject: Information on Higher Than Expected Oil Consumption Models: 2001-2006 Chevrolet Silverado 2500-3500 Series Models 2006 Chevrolet Express 2500-3500 Series Models 2001-2006 GMC Sierra 2500-3500 Series Models 2006 GMC Savana 2500-3500 Series Models 2003-2006 Chevrolet Kodiak C4500-C5500 Series Models 2003-2006 GMC Topkick C4500-C5500 Series Models with 6.6L Duramax(TM) Diesel Engine (VINs 1, 2 - RPOs LB7, LLY) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 02-06-01-027 )Section 06 - Engine/Propulsion System). Information on Engine Oil Consumption Guidelines for the 6.6L Duramax Diesel Engine. All engines require oil to lubricate and protect the load bearing and internal moving parts from wear including cylinder walls, pistons and piston rings. When a piston moves down its cylinder, a thin film of oil is left on the cylinder wall. During the combustion process, part of this oil layer is consumed. As a result, varying rates of oil consumption are accepted as normal in all engines. Oil Consumption Oil usage has a direct relationship with the amount of fuel used. The harder an engine works, the more fuel and oil it will use. Therefore, oil usage as a factor of fuel usage is a more accurate indicator of acceptable oil consumption levels than vehicle mileage. The accepted rate of oil consumption for the 6.6L Duramax(TM) Diesel engine is 0.946 liter (1 qt) within 379 liters (100 gallons) of fuel used. This rate only applies to vehicles under warranty, maintained in accordance with the appropriate maintenance schedule, driven at legal speeds and within design intent of the vehicle. Many factors can affect an owner's concern with oil consumption. Driving habits and vehicle maintenance vary from owner to owner. Thoroughly evaluate each case before deciding whether the vehicle in question has abnormal engine oil consumption. Gasket and External Leaks Inspect the oil pans, engine covers, and the engine oil cooler for leakage. Inspect the turbocharger oil lines and fittings for signs of leakage. Inspect the turbocharger outlet pipe for signs of oil, indicating worn turbocharger shaft bushings or seals. Inspect for oil leakage into the engine coolant. Improper Reading of the Oil Level Indicator (Dipstick) The vehicle must be parked on a level surface to obtain accurate oil level readings. Verify that the dipstick tube is fully seated in the block. When checking the oil level, make sure the dipstick is wiped clean before taking an oil level reading and fully depress the dipstick until the shoulder bottoms out on the dipstick tube. The dipstick should be the proper part number for the engine/vehicle that is being checked. Not Waiting Long Enough After Running Engine to Check Oil Level The vehicle should be allowed to sit for at least 15 minutes, after the engine has been shut off, before taking an oil level reading to assure the oil has had enough time to drain back into the crankcase. In order to ensure accurate results, the temperature of the oil should be close to the same temperature as the last time the oil level was checked. Improper Oil Fill After an Oil Change Following an oil change, verify that the proper amount and type of oil was put in the engine and that the oil level on the dipstick is not above the full mark or below the add marks. Refer to the Owner's Manual or Service Manual for information on recommended oil quantity, viscosity, and quality. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Diesel Engine - Greater Than Expected Oil Consumption > Page 2565 Diesel engines require a CH-4 or CG-4 oil rating. High Speed or High RPM Driving Continuous driving at high speeds/high RPMs may increase oil consumption. Because this may not always be an everyday occurrence, it is hard to determine exactly how much the oil economy will be affected. Towing or Heavy Usage Towing a trailer or hauling additional weight will increase oil consumption. Large frontal area trailers will further increase the work required from the engine, especially at highway speeds, and thus increases the rate of oil consumption. PTO Operation Operation of a PTO will increase fuel and oil usage, as the PTO driven accessory uses engine power to operate. Crankcase Ventilation System Verify that the positive crankcase ventilation (PCV) system is operating properly. Blockages, restrictions or damage to the PCV system can result in increased oil use. Oil Dilution from Condensation On vehicles that are usually driven short distances, less than 8 km (5 mi), especially in colder weather, condensation generated from cold engine operation may not get hot enough to evaporate out of the oil. When this occurs, the dipstick may indicate that the oil level is over-full. Subsequent driving on a trip of sufficient length to enable normal engine operating temperature for 30 minutes or more, in order to vaporize excess moisture, may give the customer the impression of excessive oil consumption. Engine Temperature If an engine is run at overheated temperatures (see Owner's Manual or Service Manual) for more than brief periods, oil will oxidize at a faster than normal rate. In addition, gaskets may distort, piston rings may stick, and excessive wear may result. verify that all cooling system components are in proper working order. Engine Wear Piston scuffing, excessive piston-to-wall clearance, tapered or out of round cylinders, worn, damaged or improperly installed valve guides, seals and piston rings will all cause an increase in oil consumption. Measurement of Oil Consumption Engines require a period of time to BREAK IN so that moving parts are properly seated. Therefore, oil economy should not be tested until the vehicle has accumulated at least 8000 km (5000 mi) and the oil has been changed for the first time. During initial engine break-in periods before the first oil change, oil consumption may exceed 1.9 liters (2 quarts) or more per 379 liters (100 gallons) of fuel used. 1. Verify that the engine has no external leaks. Repair as necessary. 2. Begin oil consumption test after next regularly scheduled oil and filter change. Oil changes should not be performed during the test. 3. Verify that the engine is at normal operating temperature (see Owner's Manual or Service Manual). 4. Park the vehicle on a level surface. 5. Wait at least 15 minutes, after the engine is shut off, before checking the oil level to make sure that most of the oil has had time to drain back into the crankcase. 6. Verify that the oil level is at, but not above, the full mark on the dipstick and that the proper viscosity and quality oil are being used as recommended in the Owner's Manual. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Diesel Engine - Greater Than Expected Oil Consumption > Page 2566 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Diesel Engine - Greater Than Expected Oil Consumption > Page 2567 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Diesel Engine - Greater Than Expected Oil Consumption > Page 2568 7. Dealer should record the vehicle mileage, date and engine hours at the start of the test on the Oil Consumption Worksheet shown. 8. Ask the customer to verify and record the date, odometer, oil level, fuel added, and engine hours, each time the vehicle is fueled, following steps 3-5 and return the vehicle to the dealership if the oil level is found at or below the add mark, 0.946 liter (1 qt) low, if possible. The dealer will add oil to return the oil level to full. If the oil level remains above the add mark, the customer should continue to operate the vehicle and verify the engine oil level until either the oil level drops to or below the add mark or at least 4800 km (3000 mi) has accumulated since the test began before returning to the dealership for a final evaluation. 9. If the final evaluation shows that the engine uses more than 0.946 liter (1 qt) in 379 liters (100 gallons) of fuel used, follow the published symptom diagnostics as described in the appropriate Service Manual. If the oil consumption test shows that the engine uses less than 0.946 liter (1 qt) in 379 liters (100 gallons) of fuel used, explain to the customer that their engine meets the guidelines for oil consumption. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................ 9.5L (10.0 Qt) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2571 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ................................................................ CI-4, CH-4 Grade ............................................................... ....................................................................................................................................... 15W-40 (preferred) Above 0° C (32° F) ............................................................................................................ ........................................................... 30W, 15W-40 (preferred) Below 0° C (32° F) .......................... .............................................................................................................................................................. ........... 10W-30 Below -18° C (0° F) .................................................................................................... .............................................................................................. 10W-30 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 2572 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. 2. Place a suitable container under the oil pan to drain the oil into. 3. Remove the oil drain plug. 4. Drain the engine oil. 5. Remove the oil filter. 6. Inspect to ensure the engine oil filter gasket is removed. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 2573 1. Lubricate the oil filter seal with clean engine oil. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil filter. Tighten the filter after contact plus 1 to 11⁄4 turn. 3. Install the oil pan drain plug. Tighten the plug to 84 Nm (62 ft. lbs.). 4. Lower the vehicle. 5. Fill the engine with the proper capacity and quality of engine oil. Refer to Capacities - Approximate Fluid in Maintenance and Lubrication. 6. Operate the engine, check for oil leaks, and normal oil pressure. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Power Steering ............................................................................................................................................................. 0.77 - 1.25 liters (0.81 - 1.32 quarts) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 2578 Power Steering Fluid: Fluid Type Specifications POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent POWER STEERING SYSTEM (PHT) Power Steering Fluid GM P/N 88901975 (Canadian P/N 88901976) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 2583 Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 2584 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Charge .............................................................................................................................. ........................................................... 0.7 kg (1.6 lbs) Refrigerant Charge with Front and Rear A/C ................................................................................................................................................ 1.13 kg (2.5 lb) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 2587 Refrigerant: Fluid Type Specifications Air Conditioning Refrigerant ....................................................................................................................... R134a P/N 12356150 U.S. (10953485 Canada) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 2588 Refrigerant: Service and Repair REFRIGERANT RECOVERY AND RECHARGING TOOLS REQUIRED - J 43600 ACR 2000 Air Conditioning Service Center - J 45037 A/C Oil Injector CAUTION: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. - For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. NOTE: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. - To avoid system damage use only R-134a dedicated tools when servicing the A/C system. - Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. - R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the correct amount. A/C REFRIGERANT SYSTEM OIL CHARGE REPLENISHING If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037 . For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL CAPACITIES ACCUMULATOR REPLACEMENT NOTE: Add 60 ml (2 oz) of PAG oil, plus the equal amount of oil drained from the accumulator. COMPRESSOR REPLACEMENT ......................................................................................................................................................... 60 ml (2.0 oz) NOTE:The Denso replacement compressor is precharged with 237 ml (8.0 oz) of PAG oil. CONDENSER REPLACEMENT ............................................................................................................................................................ 30 ml (1.0 oz) EVAPORATOR REPLACEMENT ......................................................................................................................................................... 90 ml (3.0 oz) NOTE: If more than the specified amount of PAG oil was drained from a component, add the equal amount drained. TOTAL SYSTEM PAG OIL CAPACITY ............................................................................................................................................ 240 ml (8.0 oz) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 2595 Refrigerant Oil: Fluid Type Specifications REFRIGERANT OIL PAG Oil GM P/N 12378526 (Canadian P/N 88900060) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2596 Refrigerant Oil: Service and Repair A/C REFRIGERANT SYSTEM OIL CHARGE REPLENISHING If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037 . For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme II Brake Fluid or equivalent DOT-3 brake fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: This procedure may be performed on all vehicles EXCEPT those equipped with option code JL4, Vehicle Stability Enhancement System (VSES). Important: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure) in Hydraulic Brakes before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Depress the brake pedal firmly and maintain steady pressure on the pedal. 4. Using the scan tool, begin the automated bleed procedure. 5. Follow the instructions on the scan tool to complete the automated bleed procedure. Release the brake pedal between each test sequence. 6. Turn the ignition OFF. 7. Remove the scan tool from the vehicle. 8. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11® GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure) in Hydraulic brakes. 10. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 11. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 12. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. Refer to Brake System External Leak Inspection in Hydraulic Brakes. 13. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 14. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes. 15. Drive the vehicle to exceed 13 kph (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 16. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 2602 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition Off and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level.Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 2603 perform the following steps: 1. Inspect the brake system for external leaks. 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 23. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 2604 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) ^ Tools Required J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 35589-A Brake Pressure Bleeder Adapter Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J 35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J 29532 , or equivalent. Add Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J 29532 , or equivalent, to the J 35589-A. 8. Charge the J 29532 , or equivalent, air tank to 175-205 kPa (25-30 psi). 9. Open the J 29532 , or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J 29532 , or equivalent, fluid tank valve, then disconnect the J 29532 , or equivalent, from the J 35589-A. 23. Remove the J 35589-A from the brake master cylinder reservoir. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 2605 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. Refer to ABS Automated Bleed Procedure in Antilock Brake System. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 28. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 2606 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11® (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports.As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling The SIR Identification Views shown below illustrate the approximate location of all SIR components available for the vehicle. This will assist in determining the appropriate SIR Disabling and Enabling for a given service procedure. Refer to See: Restraint Systems/Air Bag Systems/Locations/SIR Zone Identification Views There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: - Do not expose inflator modules to temperatures above 65°C (150°F). - Verify the correct replacement part number. Do not substitute a component from a different vehicle. - Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: - Inflatable restraint sensing and diagnostic module (SDM) - Any Inflatable restraint air bag module - Inflatable restraint steering wheel module coil - Any Inflatable restraint sensor - Inflatable restraint seat belt pretensioners - Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Important: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 2610 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-49-018A > May > 06 > Instruments - Service Tire Monitor Message is Displayed Fuse: Customer Interest Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-46-005 > Dec > 04 > OnStar(R) - System Inoperative/No LED Lamp ON Fuse: Customer Interest OnStar(R) - System Inoperative/No LED Lamp ON Bulletin No.: 04-08-46-005 Date: December 21, 2004 TECHNICAL Subject: OnStar(R) Generation 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models: 2004-2005 Buick Rainier, Rendezvous 2005 Buick Allure (Canada), LaCrosse, LeSabre, Terrazza 2004-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2005 Cadillac CTS, DeVille 2004-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2005 Chevrolet Colorado, Express, Impala, Monte Carlo, Uplander 2004-2005 GMC Denali, Denali XL, Envoy, Envoy XL, Envoy XUV, Sierra, Yukon, Yukon XL 2005 GMC Canyon, Savana 2004-2005 Pontiac Aztek 2005 Pontiac Bonneville, Grand Prix, Montana SV6, Vibe with Digital Gen 6 OnStar(R) (RPO UE1) Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module VCIM) with a Tech 2(R). Correction Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, you will need to replace the VCIM. If the VCIM is not replaced, there is the possibility that the customer will return to the dealership with the same conditions at a later date. Please contact the GM Technical Assistance Center (TAC), to obtain a new VCIM. The TAC consultant will verify your diagnosis and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a significant non-return core charge. After the VCIM has been replaced, press the blue OnStar(R) button and request a full reconfiguration. When contacting TAC regarding this concern, the availability of certain information from the vehicle will streamline the process for the dealership technician as well as minimize the time necessary for TAC to provide the correct diagnosis. Please refer to Corporate Bulletin Number 01-00-89-011B for further information concerning the information necessary before contacting TAC. Dealers in Canada should refer to GM Service Policies & Procedures Section 5.3.1 "DEALER REQUIREMENTS FOR ASSISTANCE". Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-46-005 > Dec > 04 > OnStar(R) - System Inoperative/No LED Lamp ON > Page 2624 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 07-08-45-002 > Sep > 07 > Electrical - Aftermarket Fuse Warning Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 05-08-49-018A > May > 06 > Instruments - Service Tire Monitor Message is Displayed Fuse: All Technical Service Bulletins Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 04-08-46-005 > Dec > 04 > OnStar(R) - System Inoperative/No LED Lamp ON Fuse: All Technical Service Bulletins OnStar(R) - System Inoperative/No LED Lamp ON Bulletin No.: 04-08-46-005 Date: December 21, 2004 TECHNICAL Subject: OnStar(R) Generation 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models: 2004-2005 Buick Rainier, Rendezvous 2005 Buick Allure (Canada), LaCrosse, LeSabre, Terrazza 2004-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2005 Cadillac CTS, DeVille 2004-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2005 Chevrolet Colorado, Express, Impala, Monte Carlo, Uplander 2004-2005 GMC Denali, Denali XL, Envoy, Envoy XL, Envoy XUV, Sierra, Yukon, Yukon XL 2005 GMC Canyon, Savana 2004-2005 Pontiac Aztek 2005 Pontiac Bonneville, Grand Prix, Montana SV6, Vibe with Digital Gen 6 OnStar(R) (RPO UE1) Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module VCIM) with a Tech 2(R). Correction Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, you will need to replace the VCIM. If the VCIM is not replaced, there is the possibility that the customer will return to the dealership with the same conditions at a later date. Please contact the GM Technical Assistance Center (TAC), to obtain a new VCIM. The TAC consultant will verify your diagnosis and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a significant non-return core charge. After the VCIM has been replaced, press the blue OnStar(R) button and request a full reconfiguration. When contacting TAC regarding this concern, the availability of certain information from the vehicle will streamline the process for the dealership technician as well as minimize the time necessary for TAC to provide the correct diagnosis. Please refer to Corporate Bulletin Number 01-00-89-011B for further information concerning the information necessary before contacting TAC. Dealers in Canada should refer to GM Service Policies & Procedures Section 5.3.1 "DEALER REQUIREMENTS FOR ASSISTANCE". Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 04-08-46-005 > Dec > 04 > OnStar(R) - System Inoperative/No LED Lamp ON > Page 2638 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuse: > 07-08-45-002 > Sep > 07 > Electrical - Aftermarket Fuse Warning Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Underhood Fuse Block LR Of The Engine Compartment (With RPO Code 9L4) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Underhood Fuse Block > Page 2646 Fuse: Locations I/P Fuse Block Body Control Module (BCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Underhood Fuse Block > Page 2647 Body Harness Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary Fuse: Application and ID Fuse Block - Underhood - Secondary Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 2650 Application Table Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 2651 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 2652 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 2653 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 2654 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 2655 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 2656 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 2657 Fuse: Application and ID Fuse Block - I/P Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 2658 Application Tabel Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 2659 Application Tabel Part 2 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 2660 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 2661 Fuse: Application and ID Fuse Block - Underhood Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 2662 Application Table Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 2663 Application Table Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 2664 Application Table Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 2665 Application Table Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 2666 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 2667 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 2668 Fuse: Application and ID Junction Block - I/P Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 2669 Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 2670 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 2671 Junction Block - I/P Wire Entry Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 2672 Junction Block - I/P Wire Entry Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 2673 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuse Block - Instrument Panel (IP) Fuse Block: Locations Fuse Block - Instrument Panel (IP) Body Harness Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuse Block - Instrument Panel (IP) > Page 2678 Body Control Module (BCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuse Block - Instrument Panel (IP) > Page 2679 LR Of The Engine Compartment (With RPO Code 9L4) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Fuse Block - I/P C4 (Crew Cab) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2682 Fuse Block - Underhood C1 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2683 Fuse Block - Underhood C1 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2684 Fuse Block - Underhood C1 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2685 Fuse Block - Underhood C1 Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2686 Fuse Block - Underhood C1 Part 5 Fuse Block - Underhood C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2687 Fuse Block - Underhood C2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2688 Fuse Block - Underhood C2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2689 Fuse Block - Underhood C2 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2690 Fuse Block - Underhood C2 Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2691 Fuse Block - Underhood C2 Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2692 Fuse Block - Underhood C2 Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2693 Fuse Block - Underhood C3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2694 Fuse Block - Underhood C3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2695 Fuse Block - Underhood C3 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2696 Fuse Block - Underhood C4 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2697 Fuse Block - Underhood C4 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2698 Fuse Block - Underhood C4 Part 3 Fuse Block - Underhood C5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2699 Fuse Block - Underhood C6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2700 Fuse Block - Underhood C7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2701 Fuse Block - Underhood C9 Fuse Block- I/P C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2702 Fuse Block- I/P C1 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2703 Fuse Block- I/P C1 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2704 Fuse Block- I/P C1 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2705 Fuse Block- I/P C1 Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2706 Fuse Block- I/P C1 Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2707 Fuse Block- I/P C1 Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2708 Fuse Block- I/P C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2709 Fuse Block- I/P C3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2710 Fuse Block- I/P C3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2711 Fuse Block- I/P C3 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2712 Junction Block - I/P - C2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2713 Junction Block - I/P - C2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2714 Junction Block - I/P - C4 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2715 Junction Block - I/P - C4 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2716 Junction Block - I/P - C5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2717 Junction Block - I/P - C6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2718 Junction Block - I/P - C7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2719 Junction Block - I/P - C8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2720 Junction Block - Rear Lamps - C1 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2721 Junction Block - Rear Lamps - C1 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2722 Junction Block - Rear Lamps - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2723 Junction Block - Rear Lamps - C3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2724 Junction Block - Rear Lamps - C4 Relay Block - I/P C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2725 Relay Block - I/P C1 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2726 Relay Block - I/P C1 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2727 Relay Block - I/P C1 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2728 Relay Block - I/P C1 Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2729 Relay Block - I/P C1 Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2730 Relay Block - I/P C1 Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2731 Relay Block - I/P C1 Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2732 Relay Block - I/P C3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2733 Relay Block - I/P C3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2734 Relay Block - I/P C4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2735 Relay Block - I/P C5 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2736 Relay Block - I/P C5 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2737 Relay Block - I/P C8 (With RPO Codes 5G4/5X7/5Y0/TRW) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2738 Relay Block - I/P C9 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2739 Relay Block - I/P C9 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2740 Relay Block - I/P C10 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2741 Relay Block - I/P C10 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 2742 Relay Block I/P C7 (With RPO Codes Z82 Or T89) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Fuse Block: Application and ID Fuse Block - I/P Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 2745 Application Tabel Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 2746 Application Tabel Part 2 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 2747 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 2748 Fuse Block: Application and ID Fuse Block - Underhood Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 2749 Application Table Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 2750 Application Table Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 2751 Application Table Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 2752 Application Table Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 2753 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 2754 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 2755 Fuse Block: Application and ID Fuse Block - Underhood - Secondary Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 2756 Application Table Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 2757 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 2758 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 2759 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 2760 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 2761 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 2762 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 2763 Fuse Block: Application and ID Junction Block - I/P Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 2764 Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 2765 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 2766 Junction Block - I/P Wire Entry Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 2767 Junction Block - I/P Wire Entry Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 2768 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 2771 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 2772 1. Install the engine electrical center bracket assembly to the front fender. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 4 retaining bolts (1). Tighten Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 2773 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 2774 Fuse Block: Service and Repair I/P Electrical Center or Junction Block Replacement - Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 2775 8. Install the left side end panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 2776 Fuse Block: Service and Repair I/P Electrical Center or Junction Block Replacement - Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolt. Tighten Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 2777 4. Connect the wiring connectors to the fuse block. Refer to Electrical Center Identification Views to ensure the right connections are made. 5. Install the right side end panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 2778 Fuse Block: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolts. Tighten Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 2779 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Junction Block - I/P Relay Box: Locations Junction Block - I/P Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Junction Block - I/P > Page 2784 Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Junction Block - I/P > Page 2785 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Junction Block - I/P > Page 2786 Junction Block - I/P Wire Entry Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Junction Block - I/P > Page 2787 Junction Block - I/P Wire Entry Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Junction Block - I/P > Page 2788 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Junction Block - I/P > Page 2789 Relay Box: Locations Relay Block - I/P Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Junction Block - I/P > Page 2790 Application Table Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Junction Block - I/P > Page 2791 Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 2792 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 2793 Junction Block - Rear Lamps - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 2794 Junction Block - Rear Lamps - C3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 2795 Junction Block - Rear Lamps - C4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block - I/P Relay Box: Application and ID Junction Block - I/P Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 2798 Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 2799 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 2800 Junction Block - I/P Wire Entry Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 2801 Junction Block - I/P Wire Entry Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 2802 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 2803 Relay Box: Application and ID Relay Block - I/P Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 2804 Application Table Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 2805 Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 2808 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 2809 1. Install the engine electrical center bracket assembly to the front fender. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 4 retaining bolts (1). Tighten Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 2810 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 2811 Relay Box: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolts. Tighten Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 2812 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 2813 Relay Box: Service and Repair I/P Electrical Center or Junction Block Replacement - Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 2814 8. Install the left side end panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 2815 Relay Box: Service and Repair I/P Electrical Center or Junction Block Replacement - Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolt. Tighten Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 2816 4. Connect the wiring connectors to the fuse block. Refer to Electrical Center Identification Views to ensure the right connections are made. 5. Install the right side end panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Customer Interest for Low Tire Pressure Indicator: > 05-08-49-018A > May > 06 > Instruments - Service Tire Monitor Message is Displayed Low Tire Pressure Indicator: Customer Interest Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Low Tire Pressure Indicator: > 05-08-49-018A > May > 06 > Instruments - Service Tire Monitor Message is Displayed Low Tire Pressure Indicator: All Technical Service Bulletins Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Indicator - A/T > Component Information > Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: - The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Instruments - Oil Life Monitoring System Oil Change Reminder Lamp: Technical Service Bulletins Instruments - Oil Life Monitoring System Bulletin No.: 04-06-04-045 Date: June 22, 2004 INFORMATION Subject: Oil Life Monitoring System - PCM Reset Models: 2004 All GM Passenger Cars and Trucks Important: The Oil Life Monitoring System can be found on many General Motor's vehicles prior to 2004. Refer to SI and/or the Owner's Manual for detailed information. The purpose of this bulletin is to help technicians identify which vehicles are equipped with the oil life monitoring system. Although many General Motors vehicles prior to 2004 have been equipped with the oil life monitoring system, the 2004 model year vehicles were used as a starting point to validate the system/scan tool functionality. Customers have come to depend on the Oil Life Monitoring System found on most General Motor's vehicles to inform them when it's time for an oil change. If for any reason the PCM is replaced, it is important to access the "Percent of Oil Life Remaining" from the vehicle's current PCM PRIOR to removing the PCM. This value must be programmed into the new PCM (after it is installed in the vehicle) by using the scan tool. Note: Failure to reprogram the value to the new PCM will result in missed maintenance, which may cause damage to the engine. Important: If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to changed at 5,000 km (3,000 mi) from the last engine oil change. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Page 2841 Oil Change Reminder Lamp: Description and Operation GM OIL LIFE SYSTEM When the "CHANGE ENGINE OIL" light comes on, it means that service is required for your vehicle. Have your vehicle serviced as soon as possible within the next 1 000 km (600 miles). It is possible that, if you are driving under the best conditions, the engine oil life system may not indicate that vehicle service is necessary for over a year. However, your engine oil and filter must be changed at least once a year and at this time the system must be reset. If the engine oil life system is ever reset accidentally, you must service your vehicle within 5 000 km (3,000 miles) since your last service. Remember to reset the oil life system whenever the oil is changed. Refer to GM Oil Life System - Resetting for information on the engine Oil Life System and resetting the system. When the "CHANGE ENGINE OIL" light appears, certain services, checks and inspections are required. Required services are described in the following for "Maintenance I" and "Maintenance II." Generally, it is recommended that your first service be Maintenance I, your second service be Maintenance II and that you alternate Maintenance I and Maintenance II thereafter. However, in some cases, Maintenance II may be required more often. The engine oil life monitor will indicate when to change the engine oil - usually between 5,000 km (3,000 miles) and 16,000 km (10,000 miles) since the last oil change. Under severe conditions, the "CHANGE OIL SOON" light may be displayed before 5,000 km (3,000 miles). The vehicle must not be driven more than 16,000 km (10,000 miles) or 12 months without an oil change. The engine oil life monitor will not detect dust in the oil. If the vehicle is driven in a dusty area, be sure to change the oil every 5,000 km (3,000 miles) or sooner if the "CHANGE OIL SOON" light is displayed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Page 2842 Oil Change Reminder Lamp: Service and Repair HOW TO RESET THE CHANGE ENGINE OIL MESSAGE The GM Oil Life System calculates when to change your engine oil and filter based on vehicle use. Anytime your oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where you change your oil prior to a "CHANGE ENGINE OIL" message being turned on, reset the system. To reset the "CHANGE ENGINE OIL" message, do the following: Without Driver Information Center (DIC) 1. Turn the ignition key to "RUN" with the engine off. 2. Fully press and release the accelerator pedal three times within five seconds. If the "OIL LIFE RESET" message flashes for 10 seconds, the system is resetting. 3. Turn the key to "LOCK". 4. If the "CHANGE ENGINE OIL" message comes back on when you start your vehicle, the engine oil life system has not reset. Repeat the procedure. With Driver Information Center (DIC) 1. To reset the Oil Life System use the fuel button to reach the "ENGINE OIL LIFE" screen and then press and hold the "select" button for five seconds while "ENGINE OIL LIFE" is displayed. "OIL LIFE RESET" will appear on the display for 10 seconds to let you know the system is reset. WHAT TO DO WITH USED OIL Used engine oil contains certain elements that may be unhealthy for your skin and could even cause cancer. Do not let used oil stay on your skin for very long. Clean your skin and nails with soap and water, or a good hand cleaner. Wash or properly dispose of clothing or rags containing used engine oil. See the manufacturer's warnings about the use and disposal of oil products. Used oil can be a threat to the environment. If you change your own oil, be sure to drain all the oil from the filter before disposal. Never dispose of oil by putting it in the trash, pouring it on the ground, into sewers, or into streams or bodies of water. Instead, recycle it by taking it to a place that collects used oil. If you have a problem properly disposing of your used oil, ask your dealer, a service station or a local recycling center for help. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 2858 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Customer Interest for Low Tire Pressure Indicator: > 05-08-49-018A > May > 06 > Instruments - Service Tire Monitor Message is Displayed Low Tire Pressure Indicator: Customer Interest Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Low Tire Pressure Indicator: > 05-08-49-018A > May > 06 > Instruments - Service Tire Monitor Message is Displayed Low Tire Pressure Indicator: All Technical Service Bulletins Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 2885 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Tire/Wheel - Spare Tire Is Non-Matching To Other Tires Spare Tire: Technical Service Bulletins Tire/Wheel - Spare Tire Is Non-Matching To Other Tires INFORMATION Bulletin No.: 02-03-10-001E Date: November 01, 2010 Subject: Spare Tire is a Different Size than Other Tires Models: 2002-2011 Cadillac Escalade Models 1999-2007 Chevrolet Silverado (Classic) 2000-2011 Chevrolet Suburban, Tahoe 2002-2011 Chevrolet Avalanche 1999-2007 GMC Sierra (Classic) 2001 GMC Sierra C3 2001-2011 GMC Yukon Models 2002-2011 GMC Sierra Denali Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-03-10-001D (Section 03 - Suspension). This bulletin is being issued to supply additional information concerning the spare tire on the above vehicles. You or your customers may have noticed that the spare tire has a 16-inch diameter steel wheel or 17-inch diameter aluminum wheel while the road tires have a 17-inch, 18-inch, 20-inch or 22-inch diameter aluminum wheel. Although the spare tire has a different wheel diameter and may be a different brand, the rolling circumference is nearly identical to the road tires. The size difference will not cause a concern because the spare and the other tires will travel the same distance in one revolution. This combination of non-matching tires is used most often on full-size trucks. These vehicles use a road tire and wheel combination that may be too large to conveniently fit the storage compartment space of the vehicle. The customer may not be able to easily remove the spare tire/wheel from the storage area because of its size and/or weight. A steel spare wheel, rather than an aluminum one, may be used since the spare is stowed under the vehicle where it is exposed to road and weather elements. A steel wheel is less likely to incur cosmetic damage while in the stowed position for long periods of time. Please provide this information to your customers. Also, remind your customers of the importance of following the tire maintenance schedule as listed in their Owner Manual. Additional tire care information can be found by visiting www.gmtiresafety.com or contacting GM toll-free. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2899 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2900 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2901 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 2906 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2911 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2912 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2913 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up Wheels: Customer Interest Brakes/Wheels - Excessive Debris Build Up Bulletin No.: 04-05-23-005 Date: June 22, 2004 INFORMATION Subject: Availability of Rear Wheel Mud Flaps to Reduce Debris Build-up on Rear Brake Calipers and/or Rear Wheels Models: 1999-2004 Chevrolet Silverado Pickup Models 1999-2004 GMC Sierra Pickup Models This bulletin is to inform dealers of the release of rear wheel mud flaps. The above models that are exposed to extensive off-paved roads may benefit from the mud flaps. The mud flaps have been developed to minimize the amount of stones and/or mud that can impact and collect on the rear caliper and/or wheel rim. Please advise customers that the installation of these mud flaps and following the recommended off-road driving information provided in their Owner's Manual should greatly reduce the possibility of accelerated rear brake component wear and/or rim damage. Install the mud flap forward of each rear wheel using the following procedure. Important: Always work from outboard to inboard, drilling one hole at a time and securing with a fastener. Follow the sequence of the procedure. This will prevent distortion of the mud flap. 1. Raise the vehicle. Support the vehicle. 2. Locate the pickup box side panel rear brace. 3. Remove the existing outboard upper fastener on the brace. 4. Install the mud flap through the "V" of the brace. Install the previously removed fastener in the hole (2) of the mud flap to the brace. Do not tighten the fastener at this time. 5. Using the mud flap as a template, locate and mark the location of the hole (1) in the pickup box wheel house. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up > Page 2918 Important: After drilling the holes, apply the appropriate anti-corrosion primer. Refer to the GM Refinish Material Booklet # 4901 M-D (English) or # 4901-D-F (French) for additional information. 6. Center punch the marked location and drill a 6.35 mm (1/4 in) hole. Install the plastic retainer in the hole (1) of the mud flap. 7. Tighten fastener at the hole (2) location of the mud flap. Tighten Tighten the fastener to 25 N.m (18 lb ft). 8. For vehicles with short box, use the following procedure: 8.1. Push the mud flap to make contact with the rear side of the underbody cross sill and mark the location of the hole (3) of the mud flap. 8.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 8.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 8.4. Repeat the above steps for hole locations 4 and 6. 9. For vehicles with long box, use the following procedure: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up > Page 2919 9.1. Push the mud flap to make contact with the front side of the underbody cross sill and mark location of the hole (5) of the mud flap. 9.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 9.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 9.4. Repeat the above steps for hole location 6. 10. Repeat the above steps for the opposite side. Parts Information Parts are expected to be available from GMSPO on June 30, 2004. Warranty Information Please advise the customer that the mud flaps can be purchased as an accessory. Installation and/or cost of the mud flaps will not be covered under the vehicle's warranty. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2925 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2926 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2927 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 2932 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2937 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2938 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2943 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2944 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2945 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 2950 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2955 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2956 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2957 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up Wheels: All Technical Service Bulletins Brakes/Wheels - Excessive Debris Build Up Bulletin No.: 04-05-23-005 Date: June 22, 2004 INFORMATION Subject: Availability of Rear Wheel Mud Flaps to Reduce Debris Build-up on Rear Brake Calipers and/or Rear Wheels Models: 1999-2004 Chevrolet Silverado Pickup Models 1999-2004 GMC Sierra Pickup Models This bulletin is to inform dealers of the release of rear wheel mud flaps. The above models that are exposed to extensive off-paved roads may benefit from the mud flaps. The mud flaps have been developed to minimize the amount of stones and/or mud that can impact and collect on the rear caliper and/or wheel rim. Please advise customers that the installation of these mud flaps and following the recommended off-road driving information provided in their Owner's Manual should greatly reduce the possibility of accelerated rear brake component wear and/or rim damage. Install the mud flap forward of each rear wheel using the following procedure. Important: Always work from outboard to inboard, drilling one hole at a time and securing with a fastener. Follow the sequence of the procedure. This will prevent distortion of the mud flap. 1. Raise the vehicle. Support the vehicle. 2. Locate the pickup box side panel rear brace. 3. Remove the existing outboard upper fastener on the brace. 4. Install the mud flap through the "V" of the brace. Install the previously removed fastener in the hole (2) of the mud flap to the brace. Do not tighten the fastener at this time. 5. Using the mud flap as a template, locate and mark the location of the hole (1) in the pickup box wheel house. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up > Page 2966 Important: After drilling the holes, apply the appropriate anti-corrosion primer. Refer to the GM Refinish Material Booklet # 4901 M-D (English) or # 4901-D-F (French) for additional information. 6. Center punch the marked location and drill a 6.35 mm (1/4 in) hole. Install the plastic retainer in the hole (1) of the mud flap. 7. Tighten fastener at the hole (2) location of the mud flap. Tighten Tighten the fastener to 25 N.m (18 lb ft). 8. For vehicles with short box, use the following procedure: 8.1. Push the mud flap to make contact with the rear side of the underbody cross sill and mark the location of the hole (3) of the mud flap. 8.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 8.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 8.4. Repeat the above steps for hole locations 4 and 6. 9. For vehicles with long box, use the following procedure: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up > Page 2967 9.1. Push the mud flap to make contact with the front side of the underbody cross sill and mark location of the hole (5) of the mud flap. 9.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 9.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 9.4. Repeat the above steps for hole location 6. 10. Repeat the above steps for the opposite side. Parts Information Parts are expected to be available from GMSPO on June 30, 2004. Warranty Information Please advise the customer that the mud flaps can be purchased as an accessory. Installation and/or cost of the mud flaps will not be covered under the vehicle's warranty. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2973 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2974 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2975 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 2980 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2985 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2986 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Aluminum Wheel Porosity Repair 1. Remove the tire and wheel. 2. Inflate the tire to the manufactures specified pressure as stated on the tire. 3. Submerge the tire/wheel into a water bath in order to locate the leak. 4. Inscribe a mark on the wheel in order to indicate the leak areas. 5. Inscribe a mark on the tire at the valve stem in order to Indicate the orientation of the tire to the wheel. 6. Remove the tire from the wheel. 7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. Important: Do not damage the exterior surface of the wheel. 8. Use general purpose cleaner such as 3M®, P/N 08984 or equivalent, to clean the leak area. 9. Apply 3 mm (0.12 inch) thick layer of adhesive/sealant, GM P/N 12378478 (Canadian P/N 88900041) or equivalent, to the leak area. 10. Allow for the adhesive/sealant to dry. 11. Align the inscribed mark on the tire with the valve stem on the wheel. 12. Install the tire to the wheel. 13. Inflate the tire to the manufactures specified pressure as stated on the tire. 14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 15. Balance the tire and wheel. 16. Install the tire and wheel. 17. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 2993 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing A protective clear coating covers the surface of original equipment cast aluminum wheels. A surface degradation may develop if frequent automatic car wash cleaning wears off the factory applied protective clear coating. This can happen at some automatic car wash facilities that use aggressive brushes to clean whitewalls and tires. Once you damage the protective clear coating, exposure to caustic cleaners and road salt can cause further surface deterioration. Damage to the protective clear coating is corrected by replacing the damaged wheel. Refinishing is no longer recommended. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 2994 Wheels: Service and Repair Tire and Wheel Removal and Installation Tire and Wheel Removal and Installation ^ Tools Required J 39544-KIT Complete Torque Socket Set Caution: If penetrating oil gets on the vertical surfaces between the wheel and the rotor or drum it could cause the wheel to work loose as the vehicle is driven, resulting in loss of control and an injury accident. Notice: Never use heat to loosen a tight wheel. It can shorten the life of the wheel, studs, or hub and bearing assemblies. Wheel nuts must be tightened in sequence and to the specified torque to avoid bending the wheel or rotor. Notice: Improperly tightened wheel nuts can lead to brake pulsation and rotor damage. In order to avoid expensive brake repairs, evenly tighten the wheel nuts to the proper torque specification. Important: Removing wheels can be difficult because of foreign material or a tight fit between the wheel center hole and the hub or rotor. Excessive force, such as hammering on the wheel or tire, can cause damage. Slightly tapping the tire side wall with a rubber mallet is acceptable. 1. ^ Tighten all wheel nuts on the affected wheel. 2. Loosen each wheel nut 2 turns. 3. Rock the vehicle from side to side in order to loosen the wheel. If this does not loosen the wheel, rock the vehicle front to back applying quick hard jabs to the brake pedal to loosen the wheel. 4. Repeat this procedure if the wheel does not break free. Removal Procedure 1. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to Vehicle Lifting. 2. Remove the wheel center cap. 3. Remove the wheel nuts from the tire and wheel. 4. Mark the location of the tire and wheel to the hub assembly. 5. Remove the tire and wheel from the vehicle. 6. Clean the wheel nuts, studs and the wheel and rotor mounting surfaces. Installation Procedure Caution: Before installing the wheels, remove any buildup of corrosion on the wheel mounting surface and brake drum or disc mounting surface by scraping and wire brushing. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This can cause a wheel to come off when the vehicle is moving, causing loss of control and possibly personal injury. Notice: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel stud, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 2995 1. Install the tire and wheel. Align the locating mark of the tire and wheel to the hub. 2. Install the wheel nuts. ^ Tighten the wheel nuts as shown to 190 Nm (140 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Important: ^ Tighten the nuts evenly and alternately in order to avoid excessive runout. 3. Install the wheel center cap. 4. Remove the safety stands. 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Front Hub and Bearing Assembly to Steering Knuckle Bolts ............................................................................................................... 180 Nm (133 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 2999 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Test 1-7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 3000 Wheel Bearing: Adjustments Rear Wheel Bearing Adjustment (With Full Floating 10.5" or 11.5" Ring Gear) IMPORTANT: Ensure the brakes are fully released and do not drag. ^ Pull or push the tire at the top back and forth in order to test the wheel bearing play. ^ Use a pry bar under the tire as an alternative. ^ If the wheel bearing adjustment is correct, the movement will be barely noticeable. ^ If the movement is excessive, adjust the bearings. Adjustment Procedure Tools Required J 2222-C Wheel Bearing Nut Wrench 1. Raise the vehicle. 2. Remove the axle shaft. 3. Remove the hub adjuster nut retaining ring. 4. Remove the adjuster nut lock key. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 3001 5. Tighten the wheel bearing adjusting nut using the J 2222-C. ^ Rotate the hub in the opposite direction to the way the adjuster nut is turning. ^ Ensure the inner bearing and the seal seats against the spindle shoulder. TIGHTEN ^ Adjusting nut to 70 Nm (52.0 lb ft). 6. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 7. Turn the adjusting nut clockwise until the nut contacts the bearing cone. Torque on the nut must be zero to finger tight. 8. Insert the adjusting nut lock key into the keyway using one of the following procedures: ^ If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. IMPORTANT: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. ^ If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 3002 9. Install the retaining ring. 10. Install the axle shaft. 11. Inspect the lubricant level and add, if necessary. 12. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing Wheel Bearing: Service and Repair Front Wheel Bearing Front Wheel Hub, Bearing, and Seal Replacement (4WD) ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 5. Remove the wheel drive shaft nut retaining cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 3005 6. Important: Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 3006 8. Remove the wheel hub and the 15-series bearing mounting bolts (4). 9. Remove the wheel hub and bearing (4) mounting bolts, 25/35 series. 10. Remove the wheel hub and bearing and splash shield from the vehicle. 11. Remove the O-ring seal from the steering knuckle bore, 25/35 series. 12. Remove the wheel speed sensor mounting bolt (5). 13. Clean and inspect the O-ring seal, 25/35 series. 14. Replace the seal if the following conditions exist: ^ Nicks ^ Cuts ^ Dry or brittle ^ Compression set Installation Procedure 1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 3. Install the O-ring (7) to the steering knuckle, the 25/35 series. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. ^ Tighten the sensor mounting bolt to 18 Nm (13 ft. lbs.). 5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 3007 6. Install the wheel hub and bearing (5) and splash shield (6) to the vehicle, 15 series. 7. Install the wheel hub and bearing mounting bolts, the 15 series. 8. Install the wheel hub and bearing mounting bolts, 25/35 series. ^ Tighten the wheel hub to knuckle bolts to 180 Nm (133 ft. lbs.). 9. Install the nut (2) and washer (3) retaining the wheel drive shaft assembly to the wheel hub and bearing. ^ Tighten the nut to 240 Nm (177 ft. lbs.). 10. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. ^ Tighten the brake hose clip bolt to 12 Nm (106 inch lbs.). 11. Install the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 12. Install the tire and wheel. 13. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 3008 Wheel Bearing: Service and Repair With Full Floating 10.5" or 11.5" Ring Gear Rear Axle Hub, Bearing, Cup, and/or Seal Replacement ^ Tools Required J 8092 Universal Driver Handle - 3/4 inch - 10 - J 2222-C Wheel Bearing Nut Wrench - J 24426 Wheel Bearing Race Installer - Outer - J 24427 Wheel Bearing Race Installer - Inner - J 44419 Hub Outer Bearing Race Installer - J 44420 Differential Bearing and Hub Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper. 4. Remove the axle shaft. 5. Remove the axle nut retaining ring. 6. Remove the key. 7. Remove the adjusting nut using the J 2222-C. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 3009 8. Remove the adjusting nut. 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary. 11. Remove the oil seal from the wheel hub using a suitable seal removal tool. 12. Remove the inner hub bearing. 13. Remove the inner hub bearing cup using a brass drift and a hammer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 3010 14. Remove the retaining ring from the wheel hub. 15. Remove the outer hub bearing and bearing cup using the J 24426 (2) and the J 8092 (1). Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: ^ The outer wheel bearing ^ The inner wheel bearing ^ The outer wheel bearing cup ^ The inner wheel bearing cup ^ The axle housing 2. Install the outer bearing into the wheel hub. 3. Install the outer bearing cup into the wheel hub. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 3011 4. Drive the bearing cup into the wheel hub using the J 44419 (2) and the J 8092 (1). 5. Install the retaining ring into the groove. Make sure the retaining ring is fully and evenly seated in the groove. 6. Install the inner bearing cup. 7. Drive the inner bearing cup into the wheel hub using the J 24427 (2) and the J 8092 (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 3012 8. Install the inner bearing. 9. Important: Each time you replace the wheel hub bearings, install a new oil seal in order to prevent the wheel hub from leaking. Install the new oil seal using the J 44420 (2) and the J 8092 (1). 10. Install the rotor, if necessary. 11. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. 12. Install the wheel hub to the axle housing. 13. Install the adjusting nut to the hub using the J 2222-C. 14. Adjust the wheel bearings. 15. Install the axle shaft. 16. Install the brake caliper. 17. Install the tire and wheel assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 3013 18. Inspect and add axle lubricant to the axle housing, if necessary. 19. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 3014 Wheel Bearing: Service and Repair With Rear Wheel Steering Wheel Hub and Bearing Replacement ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. 4. Remove the axle nut dust cover (4). 5. Remove the cotter pin (2) and retainer (3) from the wheel drive shaft nut. 6. Remove the wheel drive shaft retaining nut. 7. Remove the wheel hub and bearing retaining bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 3015 8. Separate the wheel drive shaft from the wheel hub and bearing using J 45859 (2) or equivalent. 9. Remove the wheel hub and bearing (1) from the vehicle. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 3016 1. Install the wheel hub and bearing (3) to the vehicle. 2. Install the wheel hub and bearing retaining bolts. ^ Tighten the bolts to 180 Nm (132 ft. lbs.). 3. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel drive shaft retaining nut. ^ Tighten the nut to 250 Nm (184 ft. lbs.). 4. Install the retainer (3) and cotter pin (2) to the wheel drive shaft nut. 5. Install the dust cap (4). 6. Install the brake rotor. 7. Install the tire and wheel. 8. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Wheels - Correct Hub Cap Installation Procedure Wheel Cover: Technical Service Bulletins Wheels - Correct Hub Cap Installation Procedure Bulletin No.: 03-03-10-002B Date: November 02, 2005 INFORMATION Subject: Use of Correct Installation Procedure for Loose Hubcap Assembly Models: 1998-2006 Chevrolet Express Van 1999-2006 Chevrolet Silverado Models 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1998-2006 GMC Savana Van 1999-2006 GMC Sierra Models 2000-2006 GMC Yukon, Yukon XL Models Supercede: This bulletin is being revised to add the 2006 model year. Please discard Corporate Bulletin Number 03-03-10-002A (Section 03 - Suspension). Some hubcap assemblies on the above-listed vehicles are being returned to the Warranty Parts Center (WPC) for loose and/or rattle conditions. Some returned hubcaps have the stand-off insulators removed. Analyses of these parts show no out of specification condition. Hubcap assemblies are placed in the vehicle by the assembly plant for dealer installation. Installation is done by threading the six or eight plastic nut caps, which are part of the hubcap assembly, to the external threads of the wheel (lug) nuts. If over-tightened, these plastic nut caps will jump threads, as designed, causing a loose or rattle condition. Important: ^ DO NOT over-tighten the plastic nut caps. ^ DO NOT use an impact wrench on the plastic nut caps. ^ DO NOT modify or remove the stand-off insulators from the plastic hubcap assembly. The nut cap system is designed to skip a thread if over-tightened. DO NOT replace the hubcap assembly if this happens. Hold hubcap (2) firmly in place on wheel with the plastic wheel nut caps (3) aligned with the steel wheel nuts (1). Hand snug each nut cap (3) (using a hand held deep socket or torque stick) until fully seated against the hubcap (2). You should feel the nut cap (3) ratchet against the hubcap (2) a couple times as the nut cap (3) seats. After all nut caps (3) have been seated, check tightness of each nut cap (3) using the socket or torque stick and tighten any nut cap (3) that may have loosened. If a nut cap (3) jumps thread (a design feature to prevent damage) and becomes loose during tightening, continue to tighten and stop short of thread jump. Follow the installation instruction sheet that is included in each hubcap package. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Wheels - Correct Hub Cap Installation Procedure > Page 3021 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Drivetrain - Wheel Drive Shaft Nut Torque Revision Axle Nut: Technical Service Bulletins Drivetrain - Wheel Drive Shaft Nut Torque Revision Bulletin No.: 04-04-95-001 Date: March 02, 2004 SERVICE MANUAL UPDATE Subject: Revised Wheel Drive Shaft Nut Torque Specification Models: 2002-2004 Cadillac Escalade, Escalade EXT 2003-2004 Cadillac Escalade ESV 1999-2004 Chevrolet Silverado 2000-2004 Chevrolet Suburban 2002-2004 Chevrolet Avalanche 2003-2004 Chevrolet Astro, Express 1999-2004 GMC Sierra 2000-2004 GMC Yukon, Yukon XL 2003-2004 GMC Safari, Savana 2003-2004 HUMMER H2 This bulletin is being issued to revise the torque specification for the wheel drive shaft nut in the Wheel Drive Shafts sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Drivetrain - Wheel Drive Shaft Nut Torque Revision > Page 3027 The torque specification for the wheel drive shaft nut has been revised as shown in the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Page 3028 Axle Nut: Specifications Axle Shaft Nut ...................................................................................................................................... ................................................ 240 Nm (177 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes Wheel Hub (Locking): Technical Service Bulletins Drivetrain - Gen II Vs. Gen III Wheel Hub Changes INFORMATION Bulletin No.: 08-03-08-003A Date: March 02, 2009 Subject: Wheel Hub Changes - Gen III vs. Gen II Models: 2008 and Prior Cadillac Escalade Models 2008 and Prior Chevrolet Avalanche, Silverado, Silverado Classic, Suburban, Tahoe 2008 and Prior GMC Sierra, Sierra Classic, Yukon Models Supercede: This bulletin is being revised to update the parts information in the table and to add an Illustrated Hub Gallery depicting all wheel hub part numbers called out below for visual identification purposes. Please discard Corporate Bulletin Number 08-03-08-003 (Section 03 - Suspension). General Motors Vehicle Engineering has introduced a new design Gen III front wheel hub for the above listed vehicles that replaces the Gen II product. These Gen II 4x2 and 4x4 applications that were previously serviced by seven part numbers are now serviced by three Gen III part numbers. Concerns have been expressed by technicians regarding the use of the new supersessions and whether the Gen III hubs will properly fit the vehicles being serviced, especially because of visual and functional differences (splines). This bulletin has been developed to address those concerns. Please refer to the table above for information on the Gen III replacement part for each Gen II application. At the end of the bulletin you will find an illustrated "Hub Gallery" with graphic depictions of both Gen II and replacement style Gen III parts. Using these illustrations you should be able to identify both the Gen II and Gen III wheel hubs. Warning If replacing wheel studs, please refer to the GM Parts Catalog for the correct stud part number for each application. Different types of studs are used depending on the wheel hub application. When replacing an older Gen II design 4x2 hub with a new 4x2/4x4 common Gen III hub, it is acceptable to have a bearing with splines on it for a 4x2 application that previously did not. However, the older Gen II design 4x4 hubs should NOT be used on a 4x2 vehicle. The Gen II 4x4 hub relies on the tension of the wheel drive shaft joint to hold everything together. The roll form feature on the inboard side of the new 4x2/4x4 Gen III hub eliminates this concern. The only hub that is not back serviceable is P/N 15719007 (not pictured) for 1999-2000 C25 applications due to a different hub flange to bearing flange offset. Important: Only the new part numbers referenced in this bulletin are interchangeable between the 4x2 and 4x4 applications with the exception of P/N 15719007 (Not Shown). Under no circumstances should any other 4x4 hub be used in a 4x2 application. Illustrated Hub Gallery Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 3033 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 3034 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 3035 The wheel hubs illustrated above are intended to provide enough visual details to identify subtle differences between the Gen II and Gen III replacement hubs. The various colors used in the graphics are not indicative of any difference or feature, but are used to increase the detail and clarity of the assembly. The associated part number is listed with each illustration. Please refer to the chart above for the specific application for each hub. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 3036 Please note the following when referring to a specific illustration: ^ When using the illustrations for back to back comparisons of two hubs, the most obvious differences are visible on the back side of the hubs. ^ The most common area of physical difference are in the shape of the four mounting bosses and their surrounds. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 3045 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 3051 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 3052 Wheel Fastener: Specifications TORQUE SPECIFICATIONS Torque Specifications Wheel Nuts .......................................................................................................................................... ................................................. 190 Nm (140 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 3053 Wheel Nut Torque Sequence Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension Wheel Fastener: Service and Repair Front Suspension Wheel Stud Replacement ^ Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel stud from the hub flange using the J 43631. 5. Remove the wheel stud from the hub flange. Installation Procedure 1. Install the new stud into the hub flange hole using firm hand pressure. 2. Install 4 washers to the new wheel stud. 3. Thread a wheel nut onto the new stud with the flat side facing the front hub flange. 4. Tighten the lug nut until the stud contacts the back of the hub flange. 5. Remove the wheel nut. 6. Remove the washers. 7. Install the brake rotor. Refer to Brake Rotor Replacement Front in Disc Brakes. 8. Install the tire and wheel. 9. Remove the safety stands. 10. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 3056 Wheel Fastener: Service and Repair Rear Suspension Wheel Stud Replacement ^ Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor, except dual wheel vehicles. 4. Remove the wheel stud from the axle flange using the J 43631. 5. Remove the axle shaft for vehicles with 9.5 in ring gear. 6. Remove the rear hub assembly for vehicles with 10.5/11.5 in ring gear, with single wheels. 7. Remove the rear axle hub for vehicles with dual wheels. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement. 8. Remove the wheel stud from the axle flange using the J 43631. 9. Remove the wheel stud from the hub flange using the J 43631. 10. Place the hub and rotor assembly in a press to remove the wheel stud. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 3057 1. Install the stud. 2. Install the 4 washers and the lug nut to the stud. 3. Tighten the lug nut in order to draw the stud into the flange until the stud fully seats. 4. Remove the lug nut and the washers. 5. Install the axle shaft for the vehicles with 9.5 in ring gear. 6. Install the rear hub assembly for the vehicles with 10.5/11.5 in ring gear, with single wheels. 7. Install the rear axle hub for vehicles with dual wheels. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement. 8. Install the rotor, except dual wheels. 9. Install the tire and wheel. 10. Remove the safety stands. 11. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Seal > Component Information > Service and Repair Wheel Seal: Service and Repair Wheel Hub, Bearing, and Seal Replacement (4WD) ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 5. Remove the wheel drive shaft nut retaining cover. 6. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Seal > Component Information > Service and Repair > Page 3061 Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent. 8. Remove the wheel hub and the 15-series bearing mounting bolts (4). 9. Remove the wheel hub and bearing (4) mounting bolts, 25/35 series. 10. Remove the wheel hub and bearing and splash shield from the vehicle. 11. Remove the O-ring seal from the steering knuckle bore, 25/35 series. 12. Remove the wheel speed sensor mounting bolt (5). 13. Clean and inspect the O-ring seal, 25/35 series. 14. Replace the seal if the following conditions exist: ^ Nicks ^ Cuts Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Seal > Component Information > Service and Repair > Page 3062 ^ Dry or brittle ^ Compression set Installation Procedure 1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 3. Install the O-ring (7) to the steering knuckle, the 25/35 series. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. ^ Tighten the sensor mounting bolt to 18 Nm (13 ft. lbs.). 5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series. 6. Install the wheel hub and bearing (5) and splash shield (6) to the vehicle, 15 series. 7. Install the wheel hub and bearing mounting bolts, the 15 series. 8. Install the wheel hub and bearing mounting bolts, 25/35 series. ^ Tighten the wheel hub to knuckle bolts to 180 Nm (133 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Seal > Component Information > Service and Repair > Page 3063 9. Install the nut (2) and washer (3) retaining the wheel drive shaft assembly to the wheel hub and bearing. ^ Tighten the nut to 240 Nm (177 ft. lbs.). 10. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. ^ Tighten the brake hose clip bolt to 12 Nm (106 inch lbs.). 11. Install the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 12. Install the tire and wheel. 13. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions Jump Starting: Service Precautions CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. - Flush any contacted areas with water immediately and thoroughly. - Get medical help. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions > Page 3067 Jump Starting: Service and Repair JUMP STARTING IN CASE OF EMERGENCY (NON HP2) CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. - Flush any contacted areas with water immediately and thoroughly. - Get medical help. NOTE: This vehicle has a 12 volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. This vehicle has a 12-volt positive, negative ground electrical system. Do not try to jump start a vehicle, if you are unsure of the other vehicle's positive voltage or ground position. The booster battery and the discharged battery should be treated carefully when using jumper cables. 1. Position the vehicle with the booster battery so that the jumper cables will comfortably reach the battery of the other vehicle. - Do not let the 2 vehicles touch. - Make sure that the jumper cables do not have loose clamps or missing insulation. 2. Perform the following steps on both vehicles: 2.1. Place the automatic transmission in PARK. 2.2. Block the wheels. 2.3. Set the parking brake. 2.4. Turn off all electrical loads that are not needed-Leave the hazard flashers ON. 2.5. Turn OFF the ignition switch. IMPORTANT: Some vehicles have a battery remote positive stud-ALWAYS use the battery remote positive stud in order to give or to receive a jump start-Consult the vehicle's owner's manual for proper connections. 3. Attach the end of one jumper cable to the positive terminal of the discharged battery. 4. Attach the other end of the first cable to the positive terminal of the booster battery. 5. Attach one end of the remaining jumper cable to the negative terminal of the booster battery. NOTE: Do not connect the negative charger lead to the housings of other vehicle electrical accessories or equipment. The action of the battery charger may damage such equipment. 6. Make the final connection of the negative jumper cable to the block or suitable bracket connected directly to the block, away from the battery. 7. Start the engine of the vehicle that is providing the jump start and turn off all electrical accessories. Raise the engine RPM to approximately 1,500 RPM. 8. Crank the engine of the vehicle with the weak battery. If the engine does not crank or cranks too slowly, perform the following steps: 8.1. Turn the ignition OFF. 8.2. Allow the booster vehicle engine to run at approximately 1,500 RPM for 5 minutes. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions > Page 3068 8.3. Attempt to start the engine of the vehicle with the discharged battery. 9. Reverse the steps exactly when removing the jumper cables. The negative battery cable must first be disconnected from the engine that was jump started. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications GThe minimum compression in any one cylinder is 2069 kPa (300 psi). There should not be more than 345 kPa (50 psi) difference between a suspect cylinder and the average compression of all 8 cylinders. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 3074 Compression Check: Testing and Inspection Engine Compression Test ^ Tools Required J 26999 Compression Gage - J 26999-20 Compression Gage Adapter - J 43244 Relay Puller Pliers 1. Ensure that the vehicle's batteries are in good condition, and fully charged. 2. Operate the vehicle until the engine is at normal operating temperature. 3. Shut off engine. 4. Disable fuel delivery system, by removing the IGN B relay with J 43244. 5. Disconnect glow plug nut; remove all 8 glow plugs. All 8 glow plugs must be removed from the engine during each cylinder test to obtain valid test results. 6. Prior to taking a compression reading, verify the cranking speed is greater than 140 RPM. If the cranking speed is below 140 RPM, repair the slow cranking speed condition before continuing with the compression test. Refer to Engine Cranks Slowly in Engine Electrical. 7. Install the J 26999-20 in the glow plug hole for the cylinder that is being checked. 8. Notice: Do not add oil to any cylinder during a compression test as extensive engine damage may result. Connect the J 26999 to the J 26999-20. 9. Using the vehicle's starter motor, rotate or crank the engine for 6 compression strokes, puffs, for the cylinder being tested. 10. Observe the J 26999 and note the reading as the compression test is being performed. A normal cylinder reading will be indicated if compression builds up quickly and evenly to the specified level. An abnormal reading will be indicated if compression is low on the first compression stroke, starts increasing on the following compression strokes but does not reach the specified level. 11. Record the compression reading for the cylinder just tested. 12. Disconnect the J 26999 from the J 26999-20 and remove adapter from the glow plug hole. 13. Repeat steps 8 through 13 for all remaining cylinders. All 8 cylinders must be tested to obtain valid test results. Record the readings. 14. The minimum compression in any one cylinder is 2069 kPa (300 psi). There should not be more than 345 kPa (50 psi) difference between a suspect cylinder and the average compression of all 8 cylinders. ^ Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. ^ Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes but does not reach normal. ^ Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > Engine - Turbocharger Lubrication Issues Camshaft Bearing: Technical Service Bulletins Engine - Turbocharger Lubrication Issues INFORMATION Bulletin No.: 03-06-93-001D Date: October 09, 2008 Subject: Diagnostic Information on Turbocharger Malfunction Due to Lack of Engine Oil for LBZ, LB7, LLY or LMM Duramax(TM) Diesel Engine Models: 2001-2009 Chevrolet Silverado 2003-2009 Chevrolet Kodiak C4500-C5500 Series 2006-2009 Chevrolet Express 2001-2009 GMC Sierra 2003-2009 GMC TopKick C4500-C5500 Series 2006-2009 GMC Savana with 6.6L Duramax(TM) V8 Diesel Engine (VINs D, 1, 2, 6 RPOs LBZ, LB7, LLY, LMM) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 03-06-93-001C (Section 06 - Engine/Propulsion System). Notice: Before installing a new turbocharger, clean any debris or excessive oil from the charge air cooler and intake system in order to prevent damage to the new turbocharger or an engine overspeed condition. Spun Camshaft Bearing If a turbocharger performance concern is thought to be caused from a deficiency of engine oil, the camshaft bearing should be checked. The number 4 camshaft bearing bore feeds the turbocharger engine oil supply hose. If this camshaft bearing spins in the bore, the turbocharger will be deprived of engine oil. This will cause a performance concern with the turbocharger. Incorrect diagnosis of this condition will result in a repeat performance concern with the turbocharger. Camshaft Bearing Inspection If the turbocharger has to be replaced, perform the following procedure in order to verify the condition of the number 4 camshaft bearing before installing a new turbocharger. 1. Remove the turbocharger. Refer to Service Information (SI) procedures for Turbocharger Replacement. 2. Remove the turbocharger oil supply hose. 3. Visually inspect for correct alignment of the number 4 camshaft bearing oil hole (Refer to illustration callout 4) through the turbocharger oil supply hole in the block (Refer to illustration callout 1). The camshaft journal oil groove (Refer to illustration callout 3) should be visible through the camshaft bearing oil hole (Refer to illustration callout 4). 4. Turn the engine over by hand a 1/2 turn. The camshaft journal oil groove (Refer to illustration callout 3) should still be visible through the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > Engine - Turbocharger Lubrication Issues > Page 3080 camshaft bearing oil hole (Refer to illustration callout 4) as the engine is turned. 5. If the camshaft bearing (Refer to illustration callout 2) has spun, the camshaft bearing oil hole (Refer to illustration callout 4) will either not be visible at all or it will be misaligned with the turbocharger oil supply hole during the inspection procedure. In the event of a spun camshaft bearing, the engine must be replaced. Restricted Turbocharger Oil Supply Hose If a lack of oil is suspected, the turbocharger oil supply hose should also be checked for damage. The turbocharger oil feed line is a high pressure plastic tube that is protected by a stainless steel braided covering. If it is twisted at all or bent too far during turbocharger removal, the plastic line may fold and kink. The kink may cause an oil flow restriction. If the plastic pipe does kink, it will not return back to its normal size and shape. The damage may not be obvious upon inspection because the braided steel covering will hide the deformity. LB7 Turbocharger Replacement During turbocharger removal on the 6.6L LB7 engine, the turbocharger oil feed line can be pulled directly away from the turbocharger body in a perpendicular fashion. Care must be taken to avoid excessive bending of the line. LBZ, LLY or LMM Turbocharger Replacement During repairs on the 6.6L LBZ, LLY or LMM engine, the EGR cooler does not allow enough perpendicular movement of the line to clear the turbocharger for removal. However, the line can be pushed straight forward of the turbocharger with less risk of kinking the line. Assistance may be required to keep the lines clear of the turbocharger during removal or installation. Notice: Do not twist the turbocharger oil supply line. Twisting of the line will result in the collapse and deformation of the plastic line, restricting oil flow and causing turbocharger performance concerns. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Camshaft Thrust Plate Bolt .................................................................................................................. ...................................................... 22 Nm (16 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 3084 Camshaft: Service and Repair Camshaft Replacement ^ Tools Required J 44643 Flywheel Holding Tool - J 26900-13 Magnetic Base - J 26900-12 Dial Indicator Removal Procedure 1. Remove the valve lifters. 2. Remove the charged air cooler. 3. Remove the air conditioning (A/C) condenser. 4. Remove the starter. 5. Install J 44643 flush to the flywheel opening. 6. Remove the engine front cover. 7. Remove the oil pump driven gear nut. 8. Remove the oil pump driven gear. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 3085 9. Important: The crankshaft reluctor and the oil pump drive gear are timed together at the factory. Do not remove the crankshaft reluctor from the oil pump drive gear. Remove the oil pump drive gear and crankshaft reluctor. ^ Do not remove the crankshaft reluctor bolts. ^ Do not damage the reluctor teeth. 10. Using J 26900-12 (1) and J 26900-13 (2), measure the camshaft end play. ^ The production value is 0.050-0.114 mm (0.002-0.0045 inch) and service limit is 0.20 mm (0.008 inch). ^ Replace the camshaft gear or the camshaft thrust plate if measured value exceeds service limit. 11. Remove the camshaft reluctor screws. 12. Remove the camshaft reluctor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 3086 13. In order to loosen the camshaft gear bolt use J 44643 in order to hold the engine from turning. 14. Loosen the camshaft gear bolt and leave the bolt finger tight. 15. Remove the camshaft thrust plate bolts through the holes in the camshaft gear. 16. Remove the camshaft with the camshaft gear attached. 17. Remove the camshaft gear bolt and discard. 18. Remove the camshaft gear. 19. Remove the camshaft thrust plate. 20. Clean and inspect the camshaft and bearings. If the camshaft bearings are worn or damaged the engine will require removal in order to replace the camshaft bearings. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 3087 1. Install the camshaft thrust plate to the camshaft. 2. Install the camshaft driven gear. 3. Install a NEW camshaft driven gear bolt.Leave the bolt finger tight. 4. Install the camshaft into the cylinder block, align the camshaft gear to the crankshaft gear as shown. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 3088 5. Apply threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the threads of the camshaft thrust plate bolts. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the camshaft thrust plate bolts. Tighten the bolts to 22 Nm (16 ft. lbs.). 7. Install the camshaft reluctor to the camshaft gear. 8. Install the camshaft reluctor bolts. Tighten the bolts in a cross-bolt pattern to 9 Nm (80 inch lbs.) . Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 3089 9. Reinstall J 44643 in the starter opening, if removed. 10. Install a NEW camshaft gear bolt. Tighten the bolt to 234 Nm (173 ft. lbs.). 11. Using J 26900-12 (1) and J 26900-13 (2) measure the camshaft end play. ^ The production value is 0.050-0.114 mm (0.002-0.0045 inch) and service limit is 0.20 mm (0.008 inch). ^ Replace the camshaft gear or the camshaft thrust plate if measured value exceeds the service limit. 12. Important: Do not damage the teeth on the crankshaft reluctor. Install the oil pump drive gear and reluctor to the crankshaft. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 3090 13. Install the oil pump driven gear. 14. Install the oil pump driven gear nut. Tighten the nut to 100 Nm (74 ft. lbs.). 15. Install the engine front cover. 16. Install the starter. 17. Install the A/C condenser. 18. Install the charged air cooler. 19. Install the valve lifters. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair Lifter / Lash Adjuster: Service and Repair Valve Lifter Replacement Removal Procedure 1. Remove the cylinder head. 2. Loosen the valve lifter guide retainer bolts. 3. Remove the valve lifter guide retainers. 4. Remove the valve lifter guides. 5. Remove the valve lifters. 6. If required, clean and inspect the lifters. Installation Procedure 1. Apply clean engine oil to the roller and outside of the valve lifter. 2. Install the valve lifter. 3. Install the valve lifter guides. 4. Install the valve lifter guide retainer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Page 3094 Notice: Refer to Fastener Notice in Service Precautions. 5. Install the valve lifter guide retainer bolt. Tighten the bolt to 11 Nm (97 inch lbs.). 6. Install the cylinder head. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair Push Rod: Service and Repair Valve Rocker Arm, Shaft, and Push Rod Replacement Removal Procedure 1. Remove the lower valve rocker arm covers. 2. Loosen the valve clearance lock nuts on each rocker arm. 3. Loosen the valve clearance adjusting screw on each rocker arm in order to relieve tension on the valvetrain. 4. Remove the rocker arm shaft assembly bolts in the sequence shown. Leave the bolts in the rocker arm shaft brackets. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Page 3098 5. Remove the rocker arm shaft assembly from the cylinder head. 6. Remove the valve bridge pins. 7. Remove the valve bridges. 8. Remove the pushrods. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Page 3099 9. Remove the rocker arm shaft bracket bolts (1), if necessary. 10. Remove the bracket (12), rocker arm (11), and spring (10), if necessary. 11. Remove the remaining rocker arms, springs, and brackets, if necessary. 12. If required, clean and inspect the valve rocker arm and shaft. Installation Procedure 1. Lubricate the rocker arm shaft (7) and the inside of the rocker arms with clean engine oil, if necessary. 2. Install the rocker arm bracket (12) and bolt (1) on one end of the rocker arm shaft, if necessary. 3. Install the intake rocker arm (9), spring (10), exhaust rocker arm (11), and bracket (12) with bolt (1). Continue in the same sequence to the last bracket, if necessary. 4. Push the bracket (12) to compress the springs and then install the bolt (1), if necessary. 5. Lubricate the top of the valves, the valve bridge stem, the valve lifter bridge, and the valve spring caps with clean engine oil. 6. Install the valve bridge. 7. Install the valve bridge pins. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Page 3100 8. Lubricate the valve lifter end of the pushrod with clean engine oil. 9. Install the pushrods.To ensure the pushrod is properly installed, gently pull up on the pushrod. Resistance should be felt from the pushrod trying to lift the valve lifter. 10. Notice: The pushrods must be correctly seated in the valve lifter and valve rocker arms before the rocker arm shaft assembly is torqued into place. Improper seating of the pushrods can cause damage to the pushrods or the valve rocker arm shaft assembly components. Install the rocker arm shaft assembly. 11. Notice: Refer to Fastener Notice in Service Precautions. Tighten the rocker arm shaft bolts in the sequence shown. Tighten the bolts to 41 Nm (30 ft. lbs.). 12. Adjust the valve clearance. 13. Install the lower valve rocker arm covers. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm, Shaft, and Push Rod Replacement Removal Procedure 1. Remove the lower valve rocker arm covers. 2. Loosen the valve clearance lock nuts on each rocker arm. 3. Loosen the valve clearance adjusting screw on each rocker arm in order to relieve tension on the valvetrain. 4. Remove the rocker arm shaft assembly bolts in the sequence shown. Leave the bolts in the rocker arm shaft brackets. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 3104 5. Remove the rocker arm shaft assembly from the cylinder head. 6. Remove the valve bridge pins. 7. Remove the valve bridges. 8. Remove the pushrods. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 3105 9. Remove the rocker arm shaft bracket bolts (1), if necessary. 10. Remove the bracket (12), rocker arm (11), and spring (10), if necessary. 11. Remove the remaining rocker arms, springs, and brackets, if necessary. 12. If required, clean and inspect the valve rocker arm and shaft. Installation Procedure 1. Lubricate the rocker arm shaft (7) and the inside of the rocker arms with clean engine oil, if necessary. 2. Install the rocker arm bracket (12) and bolt (1) on one end of the rocker arm shaft, if necessary. 3. Install the intake rocker arm (9), spring (10), exhaust rocker arm (11), and bracket (12) with bolt (1). Continue in the same sequence to the last bracket, if necessary. 4. Push the bracket (12) to compress the springs and then install the bolt (1), if necessary. 5. Lubricate the top of the valves, the valve bridge stem, the valve lifter bridge, and the valve spring caps with clean engine oil. 6. Install the valve bridge. 7. Install the valve bridge pins. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 3106 8. Lubricate the valve lifter end of the pushrod with clean engine oil. 9. Install the pushrods.To ensure the pushrod is properly installed, gently pull up on the pushrod. Resistance should be felt from the pushrod trying to lift the valve lifter. 10. Notice: The pushrods must be correctly seated in the valve lifter and valve rocker arms before the rocker arm shaft assembly is torqued into place. Improper seating of the pushrods can cause damage to the pushrods or the valve rocker arm shaft assembly components. Install the rocker arm shaft assembly. 11. Notice: Refer to Fastener Notice in Service Precautions. Tighten the rocker arm shaft bolts in the sequence shown. Tighten the bolts to 41 Nm (30 ft. lbs.). 12. Adjust the valve clearance. 13. Install the lower valve rocker arm covers. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Connecting Rod Bearing Clearance - Service Limit ........................................................................................................................... 0.10 mm (0.0039 inch) Connecting Rod Bearing Clearance - Production Value ............................................................................................ 0.036-0.077 mm (0.0014-0.0030 inch) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Connecting Rod Cap Bolt - Angular Tightening Method 1st Step ............................................................................................................................................... ................................................... 64 Nm (47 ft. lbs.) 2nd Step ............................................................. ................................................................................................................................................ 30 degrees 3rd Step ................................................................................................................................. ............................................................................. 30 degrees Connecting Rod Bearing Clearance - Service Limit ........................................................................................................................... 0.10 mm (0.0039 inch) Connecting Rod Bearing Clearance - Production Value ............................................................................................ 0.036-0.077 mm (0.0014-0.0030 inch) Connecting Rod Bore Diameter - Bearing End - Production Value ....................................................................... 62.958-62.979 mm (2.4789-2.4795 inch) Connecting Rod Bore Diameter - Pin End - Service Limit ............................................................................................................... 34.53 mm (1.3594 inch) Connecting Rod Bore Diameter - Pin End - Production Value .............................................................................. 34.512-34.522 mm (1.3587-1.3591 inch) Connecting Rod Length ....................................................................................................................... ................................................. 163.0 mm (6.42 inch) Connecting Rod Side Clearance - Service Limit ................................................................................................................................. 0.54 mm (0.0213 inch) Connecting Rod Side Clearance - Production Value ...................................................................................................... 0.31-0.49 mm (0.0122-0.0193 inch) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Technical Service Bulletins > Diesel Engine - Main Bearing Cap Bolt Identification Crankshaft Main Bearing: Technical Service Bulletins Diesel Engine - Main Bearing Cap Bolt Identification Bulletin No.: 06-06-03-003 Date: January 20, 2006 INFORMATION Subject: Information On Longer Main Bearing Cap Bolts Required For Certain 2001-2006 LB7, LLY, LBZ Duramax(TM) Diesel Engines Models: 2001-2004 Chevrolet Silverado 2003-2004 Chevrolet Kodiak C4500/C5500 Series Models 2006 Chevrolet Express Vans 2001-2004 GMC Sierra 2003-2004 GMC TopKick C4500/C5500 Series Models 2006 GMC Savana Vans with 6.6L Duramax(TM) Diesel Engine (VINs 1, 2, D - RPOs LB7, LLY, LBZ) Main Bearing Bolt Length Identification This bulletin is being published to aid technicians in how to identify the Mid-Year change to the Main Bearing Bolt Lengths. During the early production of 2006 Duramax(TM) diesel engines, a design change was made to the bearing cap bolt and bore for increased robustness. This change includes a 4 mm (0.15 in) longer main bearing cap bolt along with a deeper tapped hole and a deeper counter bore. The new bolt can be identified by a raised circle formed into the bolt head as shown in the above illustration. Note: Use of the incorrect bolt will result in engine damage. The shorter bolt will not have enough thread engagement in the newer blocks due to the deeper counter bore, and the longer bolts will bottom out in the older blocks before achieving the proper clamp load. Measurement of the bolt length is not a reliable method of identifying the bolt, as the bolts will stretch to a varying degree after installation. The main bearing cap bolts should not be reused in service. When performing service work on ANY model year Duramax(TM) engine, the main bearing cap bolts must be replaced with the same type of bolt that was originally installed. Use the raised circle identifying mark on the bolt head to determine which bolt to use. It is possible that a prior year vehicle (2001+) could have the newer block with a deeper counter bore if it had an engine replacement after the block change was implemented in production. This is possible because some long block service engines may be built with new production components, such as engine blocks. In the event that the raised circle identifying mark on the bolt head cannot be relied upon to determine the correct bolt usage, the engine block production date/time stamp may be used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Technical Service Bulletins > Diesel Engine - Main Bearing Cap Bolt Identification > Page 3118 The above engine block graphic illustration shows the location of the block's production date/time stamp behind the oil cooler. This date and time indicates the beginning of usage for the longer main bearing cap bolt. Any block built before this time will require the shorter bolt. The production date and time can be determined as follows: - 5227 = 2005, 227th day (August 15) - 1200 = 1200 hours (12:00 pm) Parts Information Parts are expected to be available from GMSPO on January 25, 2006. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Technical Service Bulletins > Page 3119 Crankshaft Main Bearing: Specifications Crankshaft Bearing Cap Bolt 1st Step ............................................................................................................................................... ................................................... 98 Nm (72 ft. lbs.) 2nd Step ............................................................. .................................................................................................................................. 132 Nm (97 ft. lbs.) 3rd Step ....................................................................................................................................... ....................................................................... 30 degrees Crankshaft Bearing Cap Bolt - Angular Tightening Method 1st Step ............................................................................................................................................... ................................................. 100 Nm (74 ft. lbs.) 2nd Step ............................................................. ................................................................................................................................................ 90 degrees Crankshaft Bearing Cap Side Bolt ............................................................................................................................................................. 70 Nm (52 ft. lbs.) Crankshaft Main Bearing Clearance - Service Limit ........................................................................................................................ 0.014 mm (0.0055 inch) Crankshaft Main Bearing Clearance - Production Value ........................................................................................... 0.039-0.070 mm (0.0015-0.0028 inch) Crankshaft Main Journal Diameter - Service Limit .......................................................................................................................... 79.89 mm (3.1453 inch) Crankshaft Main Journal Diameter - Production Value ......................................................................................... 79.905-79.925 mm (3.1459-3.1466 inch) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Crankshaft Bearing Cap Bolt 1st Step ............................................................................................................................................... ................................................... 98 Nm (72 ft. lbs.) 2nd Step ............................................................. .................................................................................................................................. 132 Nm (97 ft. lbs.) 3rd Step ....................................................................................................................................... ....................................................................... 30 degrees Crankshaft Bearing Cap Bolt - Angular Tightening Method 1st Step ............................................................................................................................................... ................................................. 100 Nm (74 ft. lbs.) 2nd Step ............................................................. ................................................................................................................................................ 90 degrees Crankshaft Bearing Cap Side Bolt ............................................................................................................................................................. 70 Nm (52 ft. lbs.) Connecting Rod Journal Diameter - Service Limit ........................................................................................................................... 62.88 mm (2.4756 inch) Connecting Rod Journal Diameter - Production Value .......................................................................................... 62.902-62.922 mm (2.4764-2.4772 inch) Crankshaft End Play - Service Limit ................................................................................................................................................... 0.54 mm (0.0213 inch) Crankshaft End Play - Production Value ...................................................................................................................... 0.04-0.205 mm (0.0016-0.0081 inch) Crankshaft Main Bearing Clearance - Service Limit ........................................................................................................................ 0.014 mm (0.0055 inch) Crankshaft Main Bearing Clearance - Production Value ........................................................................................... 0.039-0.070 mm (0.0015-0.0028 inch) Crankshaft Main Journal Diameter - Service Limit .......................................................................................................................... 79.89 mm (3.1453 inch) Crankshaft Main Journal Diameter - Production Value ......................................................................................... 79.905-79.925 mm (3.1459-3.1466 inch) Crankshaft Runout - Service Limit ..................................................................................................................................................... 0.44 mm (0.0173 inch) Crankshaft Runout - Production Value ............................................................................................................................................... 0.05 mm (0.0020 inch) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-027 > Apr > 06 > Engine Controls SES Lamp ON/False DTC's P0116/P0181 Engine Block Heater: Customer Interest Engine Controls - SES Lamp ON/False DTC's P0116/P0181 Bulletin No.: 06-06-04-027 Date: April 27, 2006 TECHNICAL Subject: LBZ, LB7, LLY, Service Engine Soon (SES) Light Illuminated, DTC P0116 or P0181 Set with Engine Coolant Heater Usage In Ambient Temperatures Above -18°C (0°F) (Replace Engine Coolant Heater Cord) Models: 2001-2006 Chevrolet Silverado 2006 Chevrolet Express Vans 2001-2006 GMC Sierra 2006 GMC Savana Vans with 6.6L Duramax(TM) Diesel V8 Engine (VINs D, 1, 2 - RPOs LBZ, LB7, LLY) Condition Some customers may comment on a Duramax(TM) Diesel vehicle with a Service Engine Soon (SES) light illuminated on the instrument cluster. Some vehicles may have been previously serviced for this same condition. Technicians may also find the following DTCs set with no concern found. ^ DTC P0116: Engine Coolant Temperature (ECT) Sensor Performance ^ DTC P0181: Fuel Temperature Sensor Performance Cause The Fuel Temperature Sensor, Engine Coolant Temperature (ECT), and Intake Air Temperature (IAT) sensors are compared to each other during a cold start to identify a concern with any one of the sensors. Engine coolant heater usage in ambient temperatures above -18°C (0°F) may trigger a false DTC P0116 or P0181. Correction The diesel supplement to the Owner's Manual advises that the engine coolant heater may be used below -1 8°C (0°F) to assist with cold starts. However, a customer may wish to plug in the heater when the overnight temperatures are unknown. A thermostatically controlled engine coolant heater cord is available for the prevention of false DTCs. This cord incorporates a thermostatic switch that only conducts below -18°C (0°F). Follow the steps below for the particular model year vehicle you are working on to ensure that the correct diagnostics are performed before replacing the engine coolant heater cord. 2001-2002 Vehicles 1. Verify that the updated calibration per Corporate Bulletin Number 02-06-04-058 has been installed. 2. Follow the published diagnostics in SI. 3. If no concern is found, determine if the customer is using the engine coolant heater above -18°C (0°F). 4. If the customer is using the engine coolant heater in ambient temperatures above -18°C (0°F), then replace the original coolant heater cord with the thermostatically controlled engine coolant heater cord, GM P/N 10369173. 2003-2006 Vehicles 1. Verify that the latest calibration has been installed. 2. Follow the published diagnostics in SI. 3. If no concern is found, determine if the customer is using the engine coolant heater above -18°C (0°F). 4. If the customer is using the engine coolant heater in ambient temperatures above -18°C (0°F), then replace the original coolant heater cord with the thermostatically controlled engine coolant heater cord, P/N 10369173. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-027 > Apr > 06 > Engine Controls SES Lamp ON/False DTC's P0116/P0181 > Page 3131 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-027 > Apr > 06 > Engine Controls - SES Lamp ON/False DTC's P0116/P0181 Engine Block Heater: All Technical Service Bulletins Engine Controls - SES Lamp ON/False DTC's P0116/P0181 Bulletin No.: 06-06-04-027 Date: April 27, 2006 TECHNICAL Subject: LBZ, LB7, LLY, Service Engine Soon (SES) Light Illuminated, DTC P0116 or P0181 Set with Engine Coolant Heater Usage In Ambient Temperatures Above -18°C (0°F) (Replace Engine Coolant Heater Cord) Models: 2001-2006 Chevrolet Silverado 2006 Chevrolet Express Vans 2001-2006 GMC Sierra 2006 GMC Savana Vans with 6.6L Duramax(TM) Diesel V8 Engine (VINs D, 1, 2 - RPOs LBZ, LB7, LLY) Condition Some customers may comment on a Duramax(TM) Diesel vehicle with a Service Engine Soon (SES) light illuminated on the instrument cluster. Some vehicles may have been previously serviced for this same condition. Technicians may also find the following DTCs set with no concern found. ^ DTC P0116: Engine Coolant Temperature (ECT) Sensor Performance ^ DTC P0181: Fuel Temperature Sensor Performance Cause The Fuel Temperature Sensor, Engine Coolant Temperature (ECT), and Intake Air Temperature (IAT) sensors are compared to each other during a cold start to identify a concern with any one of the sensors. Engine coolant heater usage in ambient temperatures above -18°C (0°F) may trigger a false DTC P0116 or P0181. Correction The diesel supplement to the Owner's Manual advises that the engine coolant heater may be used below -1 8°C (0°F) to assist with cold starts. However, a customer may wish to plug in the heater when the overnight temperatures are unknown. A thermostatically controlled engine coolant heater cord is available for the prevention of false DTCs. This cord incorporates a thermostatic switch that only conducts below -18°C (0°F). Follow the steps below for the particular model year vehicle you are working on to ensure that the correct diagnostics are performed before replacing the engine coolant heater cord. 2001-2002 Vehicles 1. Verify that the updated calibration per Corporate Bulletin Number 02-06-04-058 has been installed. 2. Follow the published diagnostics in SI. 3. If no concern is found, determine if the customer is using the engine coolant heater above -18°C (0°F). 4. If the customer is using the engine coolant heater in ambient temperatures above -18°C (0°F), then replace the original coolant heater cord with the thermostatically controlled engine coolant heater cord, GM P/N 10369173. 2003-2006 Vehicles 1. Verify that the latest calibration has been installed. 2. Follow the published diagnostics in SI. 3. If no concern is found, determine if the customer is using the engine coolant heater above -18°C (0°F). 4. If the customer is using the engine coolant heater in ambient temperatures above -18°C (0°F), then replace the original coolant heater cord with the thermostatically controlled engine coolant heater cord, P/N 10369173. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-027 > Apr > 06 > Engine Controls - SES Lamp ON/False DTC's P0116/P0181 > Page 3137 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Air Filter Element: All Technical Service Bulletins Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3143 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3144 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3145 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3146 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3147 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3148 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3149 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 3154 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 05-00-90-001 > Jan > 05 > Diesel Engine - IMPORTANT Correct Air Filter Usage Air Filter Element: All Technical Service Bulletins Diesel Engine - IMPORTANT Correct Air Filter Usage Bulletin No.: 05-00-90-001 Date: January 05, 2005 INFORMATION Subject: Information on the Proper Air Filter for the Duramax(R) Diesel Models: 2001-2005 Chevrolet Silverado 2001-2005 GMC Sierra with 6.6L Duramax(R) Diesel Engine (VINs 1, 2 - RPOs LB7, LLY) The Duramax(R) air filter, P/N 25332443, is specific to the diesel engine due to the operating characteristics of a turbo charged diesel engine. The turbo allows for a much greater air volume rate than a normal aspirated engine. The Duramax(R) diesel air filter is reinforced to eliminate damage from the increased airflow of the turbo. The reinforcement is visually identified by the five ribs of epoxy that lies across the pleats of the clean side of the filter. If the correct air filter is not used, the filter may collapse or be torn in a Duramax(R) application. This damage will allow dust and dirt to be ingested into the turbo and engine causing serious damage. This damage is usually identified at the turbo vanes as well as extreme wear in the cylinder walls of the engine. There is evidence of gasoline engine air filters being used in the Duaramax(R) application. The 8.1 gas air filter, P/N 25313349, will fit into the air box of the Duramax(R) diesel; however, it does not have the required reinforcement of the diesel air filter. The 8.1 liter gas engine air filter should never be used in a Duramax(R) diesel engine. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3164 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3165 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3166 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3167 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3168 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3169 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3170 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Block Heater: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 3175 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Cord Replacement Engine Block Heater: Service and Repair Coolant Heater Cord Replacement Coolant Heater Cord Replacement Removal Procedure 1. Raise and suitably support the vehicle. 2. Disconnect the coolant heater electrical connector (2). 3. Remove the coolant heater cord retainer and bolts. 4. Remove the coolant heater cord. Installation Procedure Notice: The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route the cord to the left front of the engine compartment securing with tie straps as necessary to prevent damage. 1. Install the coolant heater cord. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the coolant heater cord bolts and retainer. Tighten the bolts to 8 Nm (71 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Cord Replacement > Page 3182 3. Connect the coolant heater electrical connector (2). 4. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Cord Replacement > Page 3183 Engine Block Heater: Service and Repair Coolant Heater Replacement Coolant Heater Replacement (6.6L Engine) Removal Procedure 1. Drain the cooling system. 2. Remove the right front tire and wheel. 3. Remove the right engine mount. 4. Disconnect the engine coolant heater cord. 5. Loosen the coolant heater bolt. 6. Remove the engine coolant heater from the engine block. 7. Do not score the machined surface of the hole. 8. Grasp the plug with pliers. 9. Pull the plug from the engine block. 10. Clean the core plug hole in order to remove the following substances: ^ Burrs ^ Compound ^ Paint ^ Rough spots Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Cord Replacement > Page 3184 1. Coat the O-ring seal and the cleaned surface of the plug opening with water resistant high-temperature grease lubricant GM P/N 1052196 (Canadian P/N 5264008), or the equivalent. 2. Important: Avoid element contact with the inside walls of the engine block. Align the coolant heater element to point towards the top of the engine. 3. Tightly push the coolant heater into the engine block. 4. Notice: Refer to Fastener Notice in Service Precautions. Tighten the bolt on the engine coolant heater until both of the locking wings draw tightly against the inner wall of the engine block. Tighten the bolt to 2 Nm (18 inch lbs.). 5. Notice: The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route the cord to the left front of the engine compartment securing with tie straps as necessary to prevent damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Cord Replacement > Page 3185 Connect the heater cord to the coolant heater. 6. Remove the right engine mount. 7. Install the right front tire and wheel. 8. Fill the cooling system. 9. Inspect for coolant leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Balancer Bolt ................................................................................................................................................ 100 Nm (74 ft. lbs.) + 105 degrees Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3189 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Balancer Replacement ^ Tools Required J 44643 Flywheel Holding Tool Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the right wheelhouse panel. 3. Remove the starter motor bolts. Reposition the starter aside. The wiring to the starter does not require removal. 4. Install J 44643 in order to hold the flywheel. 5. Remove the lower fan shroud. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3190 6. Remove the crankshaft balancer bolt. 7. Remove the crankshaft balancer. 8. If required, clean and inspect the crankshaft balancer. Installation Procedure 1. Lubricate the crankshaft balancer internal hub with clean engine oil. 2. Install the crankshaft balancer on the crankshaft. 3. Lubricate the crankshaft balancer bolt with clean engine oil. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the crankshaft balancer bolt and washer. Tighten the bolt to 100 Nm (74 ft. lbs.) + 105 degrees. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3191 5. Remove J 44643. 6. Position the starter motor. 7. Install the starter motor bolts. Tighten the bolts to 78 Nm (58 ft. lbs.). 8. Install the right wheelhouse panel. 9. Install the lower fan shroud. 10. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston-Piston Diameter ....................................................................................................................................... 102.948-102.960 mm (4.0531-4.0535 inch) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston Ring End Gap-First Compression Ring - Service Limit ........................................................................................................... 1.37 mm (0.0539 inch) Piston Ring End Gap-First Compression Ring - Production Value .................................................................................. 0.3-0.45 mm (0.0118-0.0177 inch) Piston Ring End Gap-Second Compression Ring - Service Limit ...................................................................................................... 1.35 mm (0.0531 inch) Piston Ring End Gap-Second Compression Ring - Production Value ........................................................................... 0.50-0.65 mm (0.0197-0.0256 inch) Piston Ring End Gap-Oil Control Ring - Service Limit ...................................................................................................................... 1.20 mm (0.0472 inch) Piston Ring End Gap-Oil Control Ring - Production Value ........................................................................................... 0.15-0.35 mm (0.0059-0.0138 inch) Piston Ring to Groove Clearance-First Compression Ring - Service Limit ........................................................................................ 0.26 mm (0.0102 inch) Piston Ring to Groove Clearance-First Compression Ring - Production Value ............................................................. 0.08-0.17 mm (0.0030-0.0067 inch) Piston Ring to Groove Clearance-Second Compression Ring - Service Limit ................................................................................... 0.10 mm (0.0039 inch) Piston Ring to Groove Clearance-Second Compression Ring - Production Value ......................................................... 0.01-0.03 mm (0.0004-0.0012 inch) Piston Ring to Groove Clearance-Oil Control Ring - Service Limit ................................................................................................... 0.12 mm (0.0047 inch) Piston Ring to Groove Clearance-Oil Control Ring - Production Value ........................................................................ 0.01-0.03 mm (0.0004-0.0012 inch) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Rear Engine Plate > Component Information > Service and Repair Rear Engine Plate: Service and Repair Engine Flywheel Housing Replacement ^ Tools Required J 37228 Seal Cutter Removal Procedure 1. Drain the cooling system. 2. Remove the crankshaft rear oil seal. 3. Remove the turbocharger oil return pipe nuts from the top of the flywheel housing. 4. Remove the upper oil pan. 5. Remove the oil filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Rear Engine Plate > Component Information > Service and Repair > Page 3201 6. Remove the flywheel housing bolts, denoted by the black circles. 7. Separate the flywheel from the cylinder block using J 37228. 8. Remove the flywheel housing. 9. Remove the turbocharger oil return pipe gasket from the flywheel housing. 10. Remove the oil cooler adapter bolts. 11. Remove the oil cooler adapter and gaskets. 12. If required, clean and inspect the flywheel housing. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Rear Engine Plate > Component Information > Service and Repair > Page 3202 1. Install NEW O-ring seals to the flywheel housing, if necessary. 2. Apply a 2 mm (1/8 inch) wide bead of sealant (3) GM P/N 97720043 (Canadian P/N 88901148), or equivalent to the flywheel housing sealing surfaces. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Rear Engine Plate > Component Information > Service and Repair > Page 3203 3. Install a NEW oil cooler adapter gasket. 4. Install a NEW oil cooler adapter to flywheel housing gasket. 5. Install the oil cooler adapter to the flywheel housing. 6. Notice: Refer to Fastener Notice in Service Precautions. Install the oil cooler adapter bolts. Tighten the bolts/nuts to 21 Nm (15 ft. lbs.). 7. Install the flywheel housing bolts, denoted by the black circles. Tighten the bolts to 90 Nm (67 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Rear Engine Plate > Component Information > Service and Repair > Page 3204 8. Install the oil filter. 9. Install the upper oil pan. 10. Install a NEW gasket to the turbocharger oil return pipe. 11. Install the turbocharger oil return pipe to flywheel housing nuts. Tighten the nuts to 21 Nm (15 ft. lbs.). 12. Install the crankshaft rear oil seal. 13. Fill the cooling system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Lash ........................................................................................................................................... .................................................. 0.3 mm (0.012 inch) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 3209 Valve Clearance: Adjustments Valve Clearance Adjustment 1. Remove the fan clutch. 2. Remove the upper valve rocker arm covers. 3. Rotate the crankshaft in order to bring the number 1 cylinder to Top Dead Center (TDC) of the compression stroke. The number 1 cylinder is the front cylinder on the right bank. The mark on the crankshaft balancer should be aligned with the mark on the engine. 4. Loosen the valve adjusting screws. 5. Insert a feeler gauge between the tip of the rocker arm and the valve bridge. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 3210 6. Adjust the valve lash to 0.3 mm (0.012 inch). Refer to Valve Clearance Adjustment Specifications to determine which valves can be adjusted when the engine is at TDC. Notice: Refer to Fastener Notice in Service Precautions. 7. Tighten the lock nut. Tighten nut to 22 Nm (16 ft. lbs.). 8. Rotate the crankshaft one revolution in order to bring the number 1 cylinder to TDC of the exhaust stroke. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 3211 9. Loosen the valve adjusting screws. 10. Insert a feeler gage between the tip of the rocker arm and the valve bridge. 11. Adjust the valve clearance to 0.3 mm (0.0112 inch). Refer to Valve Clearance Adjustment Specifications to determine which valves can be adjusted when the engine is at TDC. 12. Tighten the lock nut. Tighten nut to 22 Nm (16 ft. lbs.). 13. Install the upper valve rocker arm covers. 14. Install the fan clutch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Cylinder Head Bolts > Component Information > Technical Service Bulletins > Diesel Engine - New Cyl. Head Gasket/Head Bolt Torque Cylinder Head Bolts: Technical Service Bulletins Diesel Engine - New Cyl. Head Gasket/Head Bolt Torque INFORMATION Bulletin No.: 06-06-01-006C Date: October 30, 2009 Subject: Information on 6.6L LBZ, LB7, LLY Duramax(R) Diesel Engine Cylinder Head Gasket Design Change - New Head Gasket Part Numbers and Head Bolt Torque Specifications Models: 2001-2006 Chevrolet Silverado 2003-2006 Chevrolet Kodiak C4500/5500 Series 2006 Chevrolet Express 2001-2006 GMC Sierra 2003-2006 GMC TopKick C4500/5500 Series 2006 GMC Savana with 6.6L Duramax(R) Diesel Engine (VINs D, 1, 2 - RPOs LBZ, LB7, LLY) Supercede: This bulletin is being revised to remove the Warranty Information. Please discard Corporate Bulletin Number 06-06-01-006B (Section 06 - Engine/Propulsion System). Important If a cylinder head gasket is found to be absent of thickness grade markings, refer to Service Bulletin 07-06-01-009 for gasket identification. A mid-year design change was made to the head gasket of the 2006 Duramax Diesel engine in December, 2005. This second generation gasket will service all 2001-2006 vehicles, including those with engines built using first generation gaskets. The second generation gasket will require a lower head bolt torque angle specification as well as special cleaning methods of the gasket surfaces. Gasket Identification The second generation gasket can be visually identified by its riveted construction, as opposed to the crimped design of the first generation gasket. Second Generation Head Gasket (Riveted Construction) Refer to the above illustration number (1) showing riveted construction. First Generation Head Gasket (Crimped Construction) Refer to the above illustration number (1) showing crimped construction. Special Cleaning Requirements For 2001-2006 vehicles produced with the first generation head gasket, special attention must be given to the cleaning of the engine block and cylinder head surfaces when servicing with a second generation gasket. The crimped areas (1) on the first generation gasket may, over time, allow corrosion buildup where they contact the block and cylinder head surfaces. The second generation gasket has raised ribs that seal at these crimped areas (1). A special cleaning procedure is required to ensure proper sealing. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Cylinder Head Bolts > Component Information > Technical Service Bulletins > Diesel Engine - New Cyl. Head Gasket/Head Bolt Torque > Page 3216 Cleaning Procedure 1. Remove the old head gasket using service manual procedures. Save the gasket for reference until the repair is completed. 2. Place clean rags in the cylinder bores and pushrod openings in order to keep out debris. 3. Use the J-28410 or equivalent to carefully clean the gasket sealing surface of large sealing or corrosion matter. When scraping, take care not to scratch or gouge the metal surfaces. Do not push the debris into oil, coolant, and combustion openings or bolt holes. 4. Inspect the gasket sealing surfaces for corrosion, especially in the areas that were in contact with the crimped tabs of the first generation head gasket. If corrosion is present, continue with the rest of the steps in this procedure for proper cleaning. If the sealing surface is sufficiently clean and smooth, use the revised torque specification listed towards the end of this bulletin and continue with published service manual procedures to complete the repair. 5. For surfaces that have corrosion or pitting, wrap a piece of flat steel (4"x 2" or larger) with 600 grit wet grade sand paper. Using Moisture Displacing Lubricant, P/N 88862629 (in Canada, use 89020803) or equivalent, wet sand the block surface to remove any remaining gasket material or corrosion. Do not use any paper coarser than 600 grit. Notice - Do not use any power type sanding devices. - Do not use a wire brush or wheel to clean gasket surfaces. - Do not use chemical cleaning agents on gasket surfaces. 6. Take care to keep the sanding block parallel to the block surface and evenly sand the sealing surface. Some areas of corrosion will still show a stain. Do not attempt to wet sand these areas down to a shiny metal surface. 7. Change the sanding paper when it becomes clogged. Carefully and frequently wipe the surface, using a clean cloth each time, to prevent sanding debris from building up and contaminating the oil and coolant cavities. 8. Clean the bolt threads and holes and remove the rags from the bore cavities and pushrod openings. 9. Repeat the above cleaning procedure on the cylinder head gasket surface. 10. Clean the engine block and cylinder head gasket surfaces with Brake Parts Cleaner, P/N 88862650 (in Canada, use 88901247) or equivalent, to remove any traces of oil or debris. 11. Using the revised head bolt torque specification below, reassemble the engine with NEW M12 cylinder head bolts according to service manual procedures. Torque Specification Change The second design head gasket requires a lower torque angle specification for the M12 bolts than the torque required by the first generation gasket. The M8 bolt torque remains the same for both designs. The M12 bolts on engines using the second generation head gasket should be torqued using the angular tightening method to the following specifications: Important SI will be updated with the revised torque specification. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Cylinder Head Bolts > Component Information > Technical Service Bulletins > Diesel Engine - New Cyl. Head Gasket/Head Bolt Torque > Page 3217 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm, Shaft, and Push Rod Replacement Removal Procedure 1. Remove the lower valve rocker arm covers. 2. Loosen the valve clearance lock nuts on each rocker arm. 3. Loosen the valve clearance adjusting screw on each rocker arm in order to relieve tension on the valvetrain. 4. Remove the rocker arm shaft assembly bolts in the sequence shown. Leave the bolts in the rocker arm shaft brackets. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 3221 5. Remove the rocker arm shaft assembly from the cylinder head. 6. Remove the valve bridge pins. 7. Remove the valve bridges. 8. Remove the pushrods. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 3222 9. Remove the rocker arm shaft bracket bolts (1), if necessary. 10. Remove the bracket (12), rocker arm (11), and spring (10), if necessary. 11. Remove the remaining rocker arms, springs, and brackets, if necessary. 12. If required, clean and inspect the valve rocker arm and shaft. Installation Procedure 1. Lubricate the rocker arm shaft (7) and the inside of the rocker arms with clean engine oil, if necessary. 2. Install the rocker arm bracket (12) and bolt (1) on one end of the rocker arm shaft, if necessary. 3. Install the intake rocker arm (9), spring (10), exhaust rocker arm (11), and bracket (12) with bolt (1). Continue in the same sequence to the last bracket, if necessary. 4. Push the bracket (12) to compress the springs and then install the bolt (1), if necessary. 5. Lubricate the top of the valves, the valve bridge stem, the valve lifter bridge, and the valve spring caps with clean engine oil. 6. Install the valve bridge. 7. Install the valve bridge pins. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 3223 8. Lubricate the valve lifter end of the pushrod with clean engine oil. 9. Install the pushrods.To ensure the pushrod is properly installed, gently pull up on the pushrod. Resistance should be felt from the pushrod trying to lift the valve lifter. 10. Notice: The pushrods must be correctly seated in the valve lifter and valve rocker arms before the rocker arm shaft assembly is torqued into place. Improper seating of the pushrods can cause damage to the pushrods or the valve rocker arm shaft assembly components. Install the rocker arm shaft assembly. 11. Notice: Refer to Fastener Notice in Service Precautions. Tighten the rocker arm shaft bolts in the sequence shown. Tighten the bolts to 41 Nm (30 ft. lbs.). 12. Adjust the valve clearance. 13. Install the lower valve rocker arm covers. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Lower Left Valve Cover: Service and Repair Lower Left Valve Rocker Arm Cover Replacement - Lower Left Removal Procedure 1. Remove the upper left valve rocker arm cover. 2. Remove the fuel injectors. 3. Remove the lower valve rocker arm cover bolts. 4. Remove the lower valve rocker arm cover. 5. Remove the gasket from the lower valve rocker arm cover. 6. Inspect the lower valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket. 7. If required, clean and inspect the lower valve rocker arm cover. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Lower Left > Page 3228 1. Install the lower valve rocker arm cover gasket. 2. Install the lower valve rocker arm cover. 3. Install the lower valve rocker arm cover bolts. 4. Notice: Refer to Fastener Notice in Service Precautions. Tighten the lower valve rocker arm cover bolts in the sequence shown. Tighten the bolts to 10 Nm (89 inch lbs.). 5. Install the fuel injectors. 6. Install the upper left valve rocker arm cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Lower Left > Page 3229 Valve Cover: Service and Repair Lower Right Valve Rocker Arm Cover Replacement - Lower Right Removal Procedure 1. Remove the upper right valve rocker arm cover. 2. Remove the fuel injectors. 3. Remove the lower valve rocker arm cover bolts. 4. Remove the lower valve rocker arm cover. 5. Remove the gasket from the lower valve rocker arm cover. 6. Inspect the lower valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket. 7. If required, clean and inspect the lower valve rocker arm cover. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Lower Left > Page 3230 1. Install the lower valve rocker arm cover gasket. 2. Install the lower valve rocker arm cover. 3. Install the lower valve rocker arm cover bolts. 4. Notice: Refer to Fastener Notice in Service Precautions. Tighten the bolts in the sequence shown. Tighten the bolts to 10 Nm (89 inch lbs.). 5. Install the fuel injectors. 6. Install the right upper valve rocker arm cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Lower Left > Page 3231 Valve Cover: Service and Repair Upper Left Valve Rocker Arm Cover Replacement - Upper Left Removal Procedure 1. Remove the intake manifold cover. 2. Drain the cooling system. 3. Disconnect the negative battery cable. 4. Important: After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1). 5. Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting. Remove the charged air cooler inlet duct connector (4) from the turbocharger. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Lower Left > Page 3232 6. Remove the battery cable to generator nut. 7. If equipped, remove the battery cable to the auxiliary generator. 8. Remove the battery cable harness clip from the bracket. 9. Remove the battery cable junction block bolt (1) from the power steering pump. 10. Move and secure the battery cables out of the way. 11. Disconnect the fuel lines. 12. Remove the fuel hose bracket nut. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Lower Left > Page 3233 13. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors. 14. Open the harness clip (2). 15. Remove the main engine electrical harness connectors. 16. Disconnect the barometric pressure sensor electrical connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Lower Left > Page 3234 17. Remove the main engine electrical harness connector hold down bolts. 18. Remove the main electrical connector harness bracket bolts. 19. Remove the main electrical connector harness bracket. 20. Remove the water outlet tube.. 21. Remove the auxiliary generator, if equipped. 22. Remove the positive crankcase ventilation (PCV) hose/pipe. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Lower Left > Page 3235 23. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris. 24. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal. 25. Notice: DO NOT use compressed air to clean debris from the fuel injector inlet after the fuel line is removed. Using compressed air can allow debris to enter the fuel injector inlet and damage the fuel injector. Remove the left fuel injector pipes. 26. Remove the upper valve rocker arm cover bolts. 27. Remove the upper valve rocker arm cover. 28. Remove the upper valve rocker arm cover gasket. 29. Inspect the upper valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket. 30. If required, clean and inspect the upper valve rocker arm cover. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Lower Left > Page 3236 1. Install the valve rocker arm cover gasket. 2. Install the upper valve rocker arm cover. 3. Install the upper valve rocker arm cover bolts. 4. Notice: Refer to Fastener Notice in Service Precautions. Tighten the upper valve rocker arm cover bolts in the sequence shown. Tighten the bolts to 8 Nm (71 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Lower Left > Page 3237 5. Notice: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak. Install the left fuel injector pipes. Tighten the pipes to 41 Nm (30 ft. lbs.). 6. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fittings to prevent moisture and debris from collecting between the line and fitting. 7. Install the water outlet tube.. 8. Install the auxiliary generator, if equipped. 9. Install the PCV hose/pipe. 10. Install the main electrical connector harness bracket. 11. Install the main electrical connector harness bracket bolts. Tighten the bolts to 21 Nm (15 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Lower Left > Page 3238 12. Install the main engine electrical harness connector hold down bolts. Tighten the bolts to 10 Nm (89 inch lbs.). 13. Connect the barometric pressure sensor electrical connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Lower Left > Page 3239 14. Connect the main engine electrical harness connectors. 15. Push down on the latches (1) in order to connect the connectors. 16. Close the harness clip (2). 17. Connect the fuel lines. 18. Install the fuel hose bracket nut. Tighten the nut to 21 Nm (15 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Lower Left > Page 3240 19. Position the generator positive cable. 20. Install the generator positive cable in the clip on the engine front cover. 21. Install the generator positive cable and nut. Tighten the nut to 9 Nm (80 inch lbs.). 22. Install the positive battery cable junction block bracket and bolt (1) to the power steering pump. Tighten the bolt to 9 Nm (80 inch lbs.). 23. Remove the tape from the turbocharger openings. Important: Lubricate the end of the duct prior to installation. 24. Install the charged air cooler inlet duct connector (4) to the turbocharger. 25. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1). Tighten the clamp to 6 Nm (53 inch lbs.). 26. Fill the cooling system. 27. Connect the negative battery cable. 28. Install the intake manifold cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Lower Left > Page 3241 Valve Cover: Service and Repair Upper Right Valve Rocker Arm Cover Replacement - Upper Right Removal Procedure 1. Remove the intake manifold cover. 2. Remove the air cleaner outlet duct. 3. Loosen the charged air cooler outlet duct to intake hose clamp. 4. Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting. Remove the charged air cooler outlet duct from the intake. 5. Remove the fuel injection control module. 6. Remove the Exhaust Gas Recirculation (EGR) cooler tube. 7. Remove the heater outlet hose bolt from the bracket. 8. Position the heater outlet hose out of the way. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Lower Left > Page 3242 9. Remove the fuel filter bracket bolts. 10. Reposition the fuel filter with bracket. 11. Remove the Positive Crankcase Ventilation (PCV) hose/pipe. 12. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris. 13. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal. 14. Notice: DO NOT use compressed air to clean debris from the fuel injector inlet after the fuel line is removed. Using compressed air can allow debris to enter the fuel injector inlet and damage the fuel injector. Remove the right fuel injector pipes. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Lower Left > Page 3243 15. Remove the upper valve rocker arm cover bolts. 16. Remove the upper valve rocker arm cover. 17. Remove the upper valve rocker arm cover gasket. 18. Inspect the upper valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket. 19. If required, clean and inspect the upper valve rocker arm cover. Installation Procedure 1. Install the upper valve rocker arm cover gasket. 2. Install the upper valve rocker arm cover. 3. Install the upper valve rocker arm cover bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Lower Left > Page 3244 4. Notice: Refer to Fastener Notice in Service Precautions. Tighten the upper valve rocker arm cover bolts in the sequence shown. Tighten the bolts to 8 Nm (71 inch lbs.). 5. Notice: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak. Install the fuel injector pipes. Tighten the pipes to 41 Nm (30 ft. lbs.). 6. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fittings to prevent moisture and debris from collecting between the line and fitting. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Lower Left > Page 3245 7. Install the PCV hose/pipe. 8. Position the fuel filter with bracket to the rocker cover. 9. Install the fuel filter bracket bolts. Tighten the bolts to 21 Nm (15 ft. lbs.). 10. Position the heater outlet hose. 11. Install the heater hose bracket bolt to the bracket. Tighten the bolt to 21 Nm (15 ft. lbs.). 12. Install the EGR cooler tube. 13. Install the fuel injection control module. 14. Important: Lubricate the end of the duct prior to installation. Install the charged air cooler outlet duct to the intake. 15. Tighten the charged air cooler outlet duct to intake hose clamp. Tighten the clamp to 6 Nm (53 inch lbs.). 16. Install the air cleaner outlet duct. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Lower Left > Page 3246 17. Install the intake manifold cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair Valve Spring: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement ^ Tools Required J 26999 Compression Gage - J 26999-20 Compression Gage Adapter - J 44646 Valve Spring Compressor - J 44640 Valve Stem Seal Installer Removal Procedure 1. Remove the upper and lower fan shroud. 2. Remove the valve rocker arm shaft, valve bridges, and pushrods for the cylinder head being serviced. 3. Remove the glow plug for the cylinder requiring service. 4. In order to apply shop air to the cylinders use the following procedures to modify J 26999-20 (1) and J 26999 (2): 1. Remove the valve core from J 26999-20 to allow air to flow. 2. Remove the quick connect fitting from J 26999. 3. Adapt the quick connect fitting in order to use for shop air. 4. Connect the quick connect fitting to J 26999-20. 5. Important: Rotate the cylinder to be serviced to the bottom of the stroke. This is to ensure that the engine does not rotate when the compressed air is applied to the cylinder being serviced. Install J 26999-20 into the glow plug hole for the cylinder being serviced. 6. Apply compressed air to hold the valves in place. If the compressed air is released, the valves can drop into the cylinder. 7. Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. Install J 44646 to the rocker arm bosses on the cylinder head. J 44646 should be installed in the rocker arm boss next to the cylinder being serviced. The pivot pin can be removed from the stand to allow the stand to be installed. The lever has different locating holes for the pivot pin depending on available clearance. The lever is also notched for different locations of the compressor. 8. Using J 44646 compress the valve spring. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 3250 9. Remove the valve keys (1) from the valve stem. 10. Carefully release the valve spring tension. 11. Remove the valve spring upper seat (2) and the valve spring (3). 12. Remove the valve stem oil seal (4). 13. Remove the valve spring lower seat (5). 14. Continue removing the remaining valve stem seals for the cylinder using the above procedure. Installation Procedure 1. Notice: Air pressure should remain applied to the cylinder for installation. Install the valve spring lower seat. 2. Install the valve stem seal using J 44640. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 3251 3. Install the valve spring (3), the painted end of the valve spring goes toward the cylinder head. 4. Install the valve spring upper seat (2). 5. Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. Using J 44646 compress the valve spring. 6. Install the valve keys to the valve stem. 7. Notice: The valve stem keys must correctly seat in the valve spring cap. Engine damage may occur by not installing properly. Carefully release the valve spring pressure. Make sure the valve keys stay in place. 8. Continue to install the 3 remaining valve stem seals for the cylinder. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 3252 9. Release the compressed air holding the valves in place. 10. Remove J 26999-20 (1) from the glow plug hole. 11. Continue to replace the valve stem seals on the remaining cylinders using the above procedures. 12. Install the glow plug. 13. Install the valve rocker arm shaft, the valve bridges, and the push rods. 14. Install the upper and lower fan shroud. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle Drive Belt: Customer Interest Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle TECHNICAL Bulletin No.: 05-06-01-018B Date: February 09, 2011 Subject: Accessory Drive Belt Chirp, Squeal or Squeak Type Noise at Cold Idle (Replace A/C Compressor/Power Steering Pump Mounting Bracket or Enlarge Bracket Bolt Holes) Models: 2004-2010 Chevrolet Silverado 2006-2010 Chevrolet Express 2004-2010 GMC Sierra 2006-2010 GMC Savana Equipped with 6.6L Duramax(R) Diesel Engine (VINs D, 2 - RPOs LBZ, LLY, LMM) Supercede: This bulletin is being revised to add model years and RPOs. Please discard Corporate Bulletin Number 05-06-01-018A (Section 06 - Engine/Propulsion System). Condition Important It should be noted that a chirp type noise on engine shutdown is normal for a diesel engine due to higher engine compression and the rapid stopping of the crankshaft. No repairs should be attempted for this condition. Some customers may comment on an accessory drive belt chirp, squeal, or squeak type noise at idle, especially on a cold start. The noise may be reduced or go away after the engine warms up. Cause Some 2004/2005 Silverado or Sierra trucks, with a 6.6L LLY engine produced before June, 2004, may have an A/C compressor/power steering pump mounting bracket and power steering rear mounting bracket that are machined slightly out of specification, causing a misaligned power steering pump. If the power steering pump is misaligned, it will force the accessory drive belt to run farther inboard on the fan pulley. When the belt leaves the fan pulley, the belt will not align properly to the crankshaft pulley grooves and create a chirp or squeak type noise at the point of interference. Vehicles built after June 2004 will already have the new A/C compressor/power steering pump mounting bracket installed, but still may exhibit belt noise caused by the power steering pump rear mounting bracket. Correction Vehicles built prior to June 2004, replace the A/C compressor/power steering pump mounting bracket. Vehicles built after June 2004, enlarge the rear power steering pump bracket bolt holes. 1. Follow the published service information (SI) diagnostics for drive belt chirping. The diagnostic chart for the drive belt chirping will ask to inspect for a misaligned accessory drive pulley. Important Remove the top section of the radiator shroud and TCM/cover to gain access to check alignment and measure the power steering pulley on the power steering pump shaft. 2. Verify that the power steering pulley is properly pressed onto the power steering pump shaft. Refer to SI for the power steering pulley replacement. If the pulley needs to be realigned on the power steering pump shaft, follow the published SI procedures for the power steering pulley replacement. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 3262 3. If the noise was not fully eliminated by the procedure in step 2, the power steering pulley may be adjusted with an allowable maximum variance of 1.0 mm (0.039 in) to the front from the flush position on the shaft to assist in eliminating any remaining belt noise. Refer to graphic illustration number 1 and number 2. Ensure that the power steering pump pulley illustration number 1 is flush against the power steering pump shaft illustration number 2, with an allowable variance of 1.0 mm (0.039 in). 4. If the noise was not fully eliminated by the procedure in step 3, and there are no other concerns found, follow the published SI diagnostics for drive belt chirping. Then, if the vehicle was built prior to June 2004 go to step 5. If the vehicle was built after June 2004, go to step 6. 5. Vehicles Built Prior to June 2004: 1. Replace the A/C compressor/power steering pump mounting bracket with P/N 97362175. Refer to graphic illustration number 1. Follow the published SI procedures for the Air Conditioning (A/C) Compressor and Power Steering Pump Mounting Bracket Replacement. 2. With the new A/C compressor/power steering pump mounting bracket installed, reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2") drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear power steering bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 3263 6. Vehicles Built After June 2004: 1. Remove the front and rear power steering bracket bolts from the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. 2. Reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2 in) drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Dual Generator System New belts are not available for dual generator systems. If a belt chirp noise is occurring on a dual generator system, please complete a Field Product Report (FPR). The instructions for completing a FPR can be found in Service Bulletin Number 02-00-89-002G. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 3264 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Drive Belt: Customer Interest Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3269 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3270 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3271 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3272 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3273 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3274 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3275 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-01-003 > Mar > 07 > Diesel Engine - Chirp/Squeal On Cold Start Idle Drive Belt: Customer Interest Diesel Engine - Chirp/Squeal On Cold Start Idle Bulletin No.: 07-06-01-003 Date: March 07, 2007 TECHNICAL Subject: LBZ LB7 LLY 6.6L Duramax(R) Diesel Engine Accessory Drive Belt Chirp, Squeal, or Squeak Type Noise at Cold Start Idle (Replace Accessory Drive Belt) Models: 2002-2007 Chevrolet Silverado (Classic) 2006-2007 Chevrolet Express 2003-2007 Chevrolet Kodiak C4500/C5500 Series 2002-2007 GMC Sierra (Classic) 2006-2007 GMC Savana 2003-2007 GMC TopKick C4500/C5500 Series with 6.6L Duramax(R) Diesel Engine (VINs D, 1, 2 - RPOs LBZ, LB7, LLY) Attention: Do not replace the accessory drive belt for a chirp noise during engine shutdown. This is a normal condition for a diesel engine. Condition Some customers may comment on an accessory drive belt chirp, squeal, or squeak type noise at idle, especially on a cold start. The noise may be reduced or go away after the engine warms up. Correction Refer to Service Bulletin Number 05-06-01-018A. Follow the service procedures outlined in the bulletin to diagnose and repair an accessory drive belt chirp, squeal, or squeak type noise at cold idle. If the noise was not fully eliminated by the service procedures outlined in the bulletin in step 1, then replace the accessory drive belt with a second design belt that may be less prone to noise. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-01-003 > Mar > 07 > Diesel Engine - Chirp/Squeal On Cold Start Idle > Page 3280 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-01-003 > Mar > 07 > Diesel Engine - Chirp/Squeal On Cold Start Idle > Page 3281 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle Drive Belt: All Technical Service Bulletins Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle TECHNICAL Bulletin No.: 05-06-01-018B Date: February 09, 2011 Subject: Accessory Drive Belt Chirp, Squeal or Squeak Type Noise at Cold Idle (Replace A/C Compressor/Power Steering Pump Mounting Bracket or Enlarge Bracket Bolt Holes) Models: 2004-2010 Chevrolet Silverado 2006-2010 Chevrolet Express 2004-2010 GMC Sierra 2006-2010 GMC Savana Equipped with 6.6L Duramax(R) Diesel Engine (VINs D, 2 - RPOs LBZ, LLY, LMM) Supercede: This bulletin is being revised to add model years and RPOs. Please discard Corporate Bulletin Number 05-06-01-018A (Section 06 - Engine/Propulsion System). Condition Important It should be noted that a chirp type noise on engine shutdown is normal for a diesel engine due to higher engine compression and the rapid stopping of the crankshaft. No repairs should be attempted for this condition. Some customers may comment on an accessory drive belt chirp, squeal, or squeak type noise at idle, especially on a cold start. The noise may be reduced or go away after the engine warms up. Cause Some 2004/2005 Silverado or Sierra trucks, with a 6.6L LLY engine produced before June, 2004, may have an A/C compressor/power steering pump mounting bracket and power steering rear mounting bracket that are machined slightly out of specification, causing a misaligned power steering pump. If the power steering pump is misaligned, it will force the accessory drive belt to run farther inboard on the fan pulley. When the belt leaves the fan pulley, the belt will not align properly to the crankshaft pulley grooves and create a chirp or squeak type noise at the point of interference. Vehicles built after June 2004 will already have the new A/C compressor/power steering pump mounting bracket installed, but still may exhibit belt noise caused by the power steering pump rear mounting bracket. Correction Vehicles built prior to June 2004, replace the A/C compressor/power steering pump mounting bracket. Vehicles built after June 2004, enlarge the rear power steering pump bracket bolt holes. 1. Follow the published service information (SI) diagnostics for drive belt chirping. The diagnostic chart for the drive belt chirping will ask to inspect for a misaligned accessory drive pulley. Important Remove the top section of the radiator shroud and TCM/cover to gain access to check alignment and measure the power steering pulley on the power steering pump shaft. 2. Verify that the power steering pulley is properly pressed onto the power steering pump shaft. Refer to SI for the power steering pulley replacement. If the pulley needs to be realigned on the power steering pump shaft, follow the published SI procedures for the power steering pulley replacement. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 3287 3. If the noise was not fully eliminated by the procedure in step 2, the power steering pulley may be adjusted with an allowable maximum variance of 1.0 mm (0.039 in) to the front from the flush position on the shaft to assist in eliminating any remaining belt noise. Refer to graphic illustration number 1 and number 2. Ensure that the power steering pump pulley illustration number 1 is flush against the power steering pump shaft illustration number 2, with an allowable variance of 1.0 mm (0.039 in). 4. If the noise was not fully eliminated by the procedure in step 3, and there are no other concerns found, follow the published SI diagnostics for drive belt chirping. Then, if the vehicle was built prior to June 2004 go to step 5. If the vehicle was built after June 2004, go to step 6. 5. Vehicles Built Prior to June 2004: 1. Replace the A/C compressor/power steering pump mounting bracket with P/N 97362175. Refer to graphic illustration number 1. Follow the published SI procedures for the Air Conditioning (A/C) Compressor and Power Steering Pump Mounting Bracket Replacement. 2. With the new A/C compressor/power steering pump mounting bracket installed, reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2") drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear power steering bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 3288 6. Vehicles Built After June 2004: 1. Remove the front and rear power steering bracket bolts from the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. 2. Reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2 in) drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Dual Generator System New belts are not available for dual generator systems. If a belt chirp noise is occurring on a dual generator system, please complete a Field Product Report (FPR). The instructions for completing a FPR can be found in Service Bulletin Number 02-00-89-002G. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 3289 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics Drive Belt: All Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 3294 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 3295 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Drive Belt: All Technical Service Bulletins Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3300 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3301 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3302 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3303 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3304 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3305 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3306 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-06-01-003 > Mar > 07 > Diesel Engine - Chirp/Squeal On Cold Start Idle Drive Belt: All Technical Service Bulletins Diesel Engine - Chirp/Squeal On Cold Start Idle Bulletin No.: 07-06-01-003 Date: March 07, 2007 TECHNICAL Subject: LBZ LB7 LLY 6.6L Duramax(R) Diesel Engine Accessory Drive Belt Chirp, Squeal, or Squeak Type Noise at Cold Start Idle (Replace Accessory Drive Belt) Models: 2002-2007 Chevrolet Silverado (Classic) 2006-2007 Chevrolet Express 2003-2007 Chevrolet Kodiak C4500/C5500 Series 2002-2007 GMC Sierra (Classic) 2006-2007 GMC Savana 2003-2007 GMC TopKick C4500/C5500 Series with 6.6L Duramax(R) Diesel Engine (VINs D, 1, 2 - RPOs LBZ, LB7, LLY) Attention: Do not replace the accessory drive belt for a chirp noise during engine shutdown. This is a normal condition for a diesel engine. Condition Some customers may comment on an accessory drive belt chirp, squeal, or squeak type noise at idle, especially on a cold start. The noise may be reduced or go away after the engine warms up. Correction Refer to Service Bulletin Number 05-06-01-018A. Follow the service procedures outlined in the bulletin to diagnose and repair an accessory drive belt chirp, squeal, or squeak type noise at cold idle. If the noise was not fully eliminated by the service procedures outlined in the bulletin in step 1, then replace the accessory drive belt with a second design belt that may be less prone to noise. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-06-01-003 > Mar > 07 > Diesel Engine - Chirp/Squeal On Cold Start Idle > Page 3311 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-06-01-003 > Mar > 07 > Diesel Engine - Chirp/Squeal On Cold Start Idle > Page 3312 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 04-06-01-013 > Apr > 04 > Engine - Serpentine Drive Belt Wear Information Drive Belt: All Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics Drive Belt: All Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 3322 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 3323 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 04-06-01-013 > Apr > 04 > Engine - Serpentine Drive Belt Wear Information Drive Belt: All Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 3328 Drive Belt: Diagrams With RPO LLY With RPO LLY (Dual Generators) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 3329 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: ^ The drive belt ^ The drive belt tensioner ^ The drive belt idler pulley ^ The crankshaft balancer pulley ^ The accessory drive component mounting brackets ^ The accessory drive components ^ The power steering pump, if belt driven ^ The generator ^ The A/C compressor, if equipped ^ The engine cooling fan, if belt driven ^ The water pump, if belt driven ^ The vacuum pump, if equipped ^ The air compressor, if equipped The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. There also may be a V-belt style belt used to drive certain accessory drive components. The drive belts are made of different types of rubbers,chloroprene or EPDM, and have different layers or plys containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The chirping noise may be intermittent due to moisture on the drive belt or the accessory drive pulleys. In order to duplicate the customer's concern, it may be necessary to spray a small amount of water onto the drive belt. If spraying water onto the drive belt duplicates the symptom, cleaning the accessory belt pulleys may be the most probable solution. A loose or improper installation of a body or suspension component, or other item(s) on the vehicle may also cause the chirping noise. Test Description Steps 1 - 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3332 Steps 3(continued) - 15 The numbers below refer to the steps in the diagnostic table. 2. The chirping noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Remove the drive belt and operate the engine for a few seconds, this will verify if the chirping noise is related to the drive belt or not. With the drive belt removed the cooling fan will not operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt removed. 4. Inspect the drive belt for signs of pilling. Pilling is the small balls, pills or strings in the drive belt grooves caused by the accumulation of rubber dust. 6. Misalignment of the accessory drive pulleys may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 10. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 12. Inspection of the accessory drive pulleys should include inspecting for bends, dents, or other damage to the pulleys that would prevent the drive belt from seating properly in the pulley grooves, or on the smooth surface of the pulley when the back side of the drive belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3333 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt is usually caused by incorrect installation or the incorrect drive belt for the application. Minor misalignment of the accessory drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or fall off. Excessive misalignment of the accessory drive belt pulleys will cause excessive wear and may also make the drive belt fall off. Test Description Steps 1 - 6 The numbers below refer to the steps in the diagnostic table. 2. This inspection is to verify the drive belt is correctly installed on all of the accessory drive pulleys. Wear on the drive belt may be caused by mis-positioning the drive belt by one groove on a pulleys. 3. The installation of a drive belt that is too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on the pulleys. 4. This inspection is to verify the drive belt is not contacting any part of the engine or body while the engine is operating. There should be sufficient clearance when the accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3334 Drive Belt: Testing and Inspection Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the accessory drive belt pulleys, this may be caused by a pulley misalignment. An extra load that is quickly applied or released by an accessory drive component may cause the drive belt to fall off. Verify that the accessory drive components are operating properly. If the drive belt is the incorrect length, the drive belt tensioner may not maintain the proper tension on the drive belt. Test Description Step 1 - 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3335 Steps 3 - 12 The numbers below refer to the steps in the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. Inspect the drive belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the accessory drive pulleys may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure of that pulley. 5. Inspection of the accessory drive pulleys should include inspecting for bends, dents, or other damage to the pulleys that would prevent the drive belt from seating properly in the pulley grooves or on the smooth surface of a pulley when the back side of the drive belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will also cause the drive belt to fall off. 7. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. Missing, loose, or incorrect fasteners may cause pulley misalignment from the accessory drive brackets moving under load. Over tightening the fasteners may cause misalignment of the accessory component brackets. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3336 Drive Belt: Testing and Inspection Drive Belt Rumbling Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If, after replacing the drive belt and completing the diagnostic table, the rumbling is only heard with the drive belt installed, there might be an accessory drive component failure. Varying the load on the accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description Steps 1 - 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3337 The numbers below refer to the steps on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt is causing the rumbling. Rumbling may be confused with an internal engine noise due to the similarity in the description. Operate the engine for a few seconds, this will verify if the rumbling noise is related to the drive belt or not. With the drive belt removed the cooling fan will not operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt removed. 4. Inspect the drive belt to ensure that the drive belt is not the cause of the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating, this may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is a normal condition and acceptable. When the pilling is severe, the drive belt does not have a smooth surface for proper operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3338 Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The chirping noise may be intermittent due to moisture on the drive belt or the accessory drive pulleys. In order to duplicate the customer's concern, it may be necessary to spray a small amount of water onto the drive belt. If spraying water onto the drive belt duplicates the symptom, cleaning the accessory belt pulleys may be the most probable solution. A loose or improper installation of a body or suspension component, or other item(s) on the vehicle may also cause the chirping noise. Test Description Steps 1 - 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3339 Steps 3(continued) - 15 The numbers below refer to the steps in the diagnostic table. 2. The chirping noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Remove the drive belt and operate the engine for a few seconds, this will verify if the chirping noise is related to the drive belt or not. With the drive belt removed the cooling fan will not operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt removed. 4. Inspect the drive belt for signs of pilling. Pilling is the small balls, pills or strings in the drive belt grooves caused by the accumulation of rubber dust. 6. Misalignment of the accessory drive pulleys may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 10. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 12. Inspection of the accessory drive pulleys should include inspecting for bends, dents, or other damage to the pulleys that would prevent the drive belt from seating properly in the pulley grooves, or on the smooth surface of the pulley when the back side of the drive belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Drive Belt Excessive Wear Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3340 Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt is usually caused by incorrect installation or the incorrect drive belt for the application. Minor misalignment of the accessory drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or fall off. Excessive misalignment of the accessory drive belt pulleys will cause excessive wear and may also make the drive belt fall off. Test Description Steps 1 - 6 The numbers below refer to the steps in the diagnostic table. 2. This inspection is to verify the drive belt is correctly installed on all of the accessory drive pulleys. Wear on the drive belt may be caused by mis-positioning the drive belt by one groove on a pulleys. 3. The installation of a drive belt that is too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on the pulleys. 4. This inspection is to verify the drive belt is not contacting any part of the engine or body while the engine is operating. There should be sufficient clearance when the accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the accessory drive belt pulleys, this may be caused by a pulley misalignment. An extra load that is quickly applied or released by an accessory drive component may cause the drive belt to fall off. Verify that the accessory drive components are operating properly. If the drive belt is the incorrect length, the drive belt tensioner may not maintain the proper tension on the drive belt. Test Description Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3341 Step 1 - 2 Steps 3 - 12 The numbers below refer to the steps in the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. Inspect the drive belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the accessory drive pulleys may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure of that pulley. 5. Inspection of the accessory drive pulleys should include inspecting for bends, dents, or other damage to the pulleys that would prevent the drive belt from seating properly in the pulley grooves or on the smooth surface of a pulley when the back side of the drive belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will also cause the drive belt to fall off. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3342 7. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. Missing, loose, or incorrect fasteners may cause pulley misalignment from the accessory drive brackets moving under load. Over tightening the fasteners may cause misalignment of the accessory component brackets. Drive Belt Rumbling Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If, after replacing the drive belt and completing the diagnostic table, the rumbling is only heard with the drive belt installed, there might be an accessory drive component failure. Varying the load on the accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3343 Steps 1 - 8 The numbers below refer to the steps on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt is causing the rumbling. Rumbling may be confused with an internal engine noise due to the similarity in the description. Operate the engine for a few seconds, this will verify if the rumbling noise is related to the drive belt or not. With the drive belt removed the cooling fan will not operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt removed. 4. Inspect the drive belt to ensure that the drive belt is not the cause of the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating, this may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is a normal condition and acceptable. When the pilling is severe, the drive belt does not have a smooth surface for proper operation. Drive Belt Squeal Drive Belt Squeal Diagnosis Diagnostic Aids A loose or improper installation of a body or suspension component, or other items on the vehicle may cause the squeal noise. If the squeal is intermittent, verify that it is not the accessory drive components by varying their loads, making sure they are operating to their maximum capacity. An overcharged air conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing generator are suggested items to inspect. Test Description Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3344 Steps 1 - 5 Steps 5 (continued) - 9 The number(s) below refer to the steps in the diagnostic table. 2. The squeal may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise, do not proceed further with this table 3. The squeal may be an internal engine noise. Remove the drive belt and operate the engine for a few seconds, this will verify if the squealing noise is related to the drive belt or an accessory drive component. With the drive belt removed the cooling fan will not be operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt removed. 4. This test is to verify that an accessory drive components does not have a seized bearing. With the belt removed, test the bearings in the accessory drive components for smooth operation. Also test the accessory drive components with the engine operating by varying the load on the accessory drive components to verify that the components is operating properly. 5. This test is to verify that the drive belt tensioner is operating properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squealing noise. 6. This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from operating properly. Also if the incorrect Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3345 length drive belt was installed, it may not be routed correctly and may be turning an accessory drive component in the incorrect direction. 7. Misalignment of the accessory drive pulleys may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley. 8. Inspect the accessory drive pulleys to verify that they are the correct diameter or width. Using a known good vehicle, compare the accessory drive pulleys. Drive Belt Vibration Drive Belt Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. An overcharged Air Conditioning (A/C) system, a power steering system restriction, or the incorrect fluid, or an extra load placed on the generator are suggested items to inspect. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Test Description Steps 1 - 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3346 Steps 10 - 11 The numbers below refer to the steps in the diagnostic table. 2. This test is to verify that the vibration is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belt or accessory drive components may be causing the vibration. Remove the drive belt and operate the engine for a few seconds, this will verify if the vibration is related to the drive belt or not. With the drive belt removed the water pump will not operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt removed. 4. The drive belt may cause a vibration. While the drive belt is removed this is the best time to inspect the condition of the drive belt. 6. Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smooth operation. Inspect for a bent fan shaft or bent mounting flange. 9. Inspect the water pump drive shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known good water pump. 10. Accessory drive component brackets that are bent, cracked, or loose may put an extra strain on that accessory drive component causing it to vibrate. Drive Belt Whine Drive Belt Whine Diagnosis Diagnostic Aids The drive belt will not cause the whine. If the whine is intermittent, verify that it is not the accessory drive components by varying their loads, making sure they are operating to their maximum capacity. An overcharged air conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing generator are suggested items to inspect. Test Description Steps 1 - 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 3347 Steps 3 - 5 The numbers below refer to the steps in the diagnostic table. 3. This test is to verify that the whine is being caused by the accessory drive components. Remove the drive belt and operate the engine for a few seconds, this will verify if the whining noise is related to the accessory drive component. With the drive belt removed the cooling fan will not operate and the engine may overheat. Also Diagnostic Trouble Codes (DTCs) may set when the engine is operated with the drive belt removed. 4. The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the proper removal and replacement procedure. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 3348 Drive Belt: Service and Repair Drive Belt Replacement Removal Procedure 1. Install a 3/8 inch breaker bar into the tensioner opening and rotate the tensioner counterclockwise. 2. Remove the belt from the tensioner. 3. Slowly release the tension on the tensioner arm. 4. Remove the drive belt from the drive pulleys, if equipped with a single generator. 5. Remove the drive belt from the drive pulleys, if equipped with dual generators. 6. Remove the drive belt from the vehicle. 7. Inspect the drive belt for excessive cracking or any visible damage, replace if necessary. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 3349 1. Install the drive belt to the vehicle. 2. Route the drive belt over and/or around all the drive pulleys except for the tensioner, if equipped with dual generators. 3. Route the drive belt over and/or around all the drive pulleys except for the tensioner, if equipped with a single generator. 4. Install a 3/8 inch breaker bar into the tensioner opening and rotate the tensioner counterclockwise. 5. Install the belt to the tensioner. 6. Slowly release the tension on the tensioner arm. 7. Inspect the drive belt for proper installation on and/or around all pulleys. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection Drive Belt Tensioner: Testing and Inspection Drive Belt Tensioner Diagnosis 1. Notice: Allowing the drive belt tensioner to snap into the free position may result in damage to the tensioner. Important: When the engine is operating the drive belt tensioner arm will move. Do not replace the drive belt tensioner because of movement in the drive belt tensioner arm. Remove the drive belt. 2. Position a 3/8 inch drive breaker bar into the drive belt tensioner opening and rotate the tensioner counterclockwise. 3. Move the drive belt tensioner through it's full travel. ^ The movement should feel smooth ^ There should be no binding ^ The tensioner should return freely 4. If any binding is observed, replace the drive belt tensioner. 5. Install the drive belt. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection > Page 3353 Drive Belt Tensioner: Service and Repair Drive Belt Tensioner Replacement Removal Procedure 1. Remove the drive belt. 2. Remove the drive belt tensioner bolt. 3. Remove the drive belt tensioner. Installation Procedure 1. Install the drive belt tensioner. Align the pin with the hole in the generator bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the drive belt tensioner bolt. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection > Page 3354 Tighten bolt to 50 Nm (37 ft. lbs.). 3. Install the drive belt. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle Engine Accessory Bracket: Customer Interest Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle TECHNICAL Bulletin No.: 05-06-01-018B Date: February 09, 2011 Subject: Accessory Drive Belt Chirp, Squeal or Squeak Type Noise at Cold Idle (Replace A/C Compressor/Power Steering Pump Mounting Bracket or Enlarge Bracket Bolt Holes) Models: 2004-2010 Chevrolet Silverado 2006-2010 Chevrolet Express 2004-2010 GMC Sierra 2006-2010 GMC Savana Equipped with 6.6L Duramax(R) Diesel Engine (VINs D, 2 - RPOs LBZ, LLY, LMM) Supercede: This bulletin is being revised to add model years and RPOs. Please discard Corporate Bulletin Number 05-06-01-018A (Section 06 - Engine/Propulsion System). Condition Important It should be noted that a chirp type noise on engine shutdown is normal for a diesel engine due to higher engine compression and the rapid stopping of the crankshaft. No repairs should be attempted for this condition. Some customers may comment on an accessory drive belt chirp, squeal, or squeak type noise at idle, especially on a cold start. The noise may be reduced or go away after the engine warms up. Cause Some 2004/2005 Silverado or Sierra trucks, with a 6.6L LLY engine produced before June, 2004, may have an A/C compressor/power steering pump mounting bracket and power steering rear mounting bracket that are machined slightly out of specification, causing a misaligned power steering pump. If the power steering pump is misaligned, it will force the accessory drive belt to run farther inboard on the fan pulley. When the belt leaves the fan pulley, the belt will not align properly to the crankshaft pulley grooves and create a chirp or squeak type noise at the point of interference. Vehicles built after June 2004 will already have the new A/C compressor/power steering pump mounting bracket installed, but still may exhibit belt noise caused by the power steering pump rear mounting bracket. Correction Vehicles built prior to June 2004, replace the A/C compressor/power steering pump mounting bracket. Vehicles built after June 2004, enlarge the rear power steering pump bracket bolt holes. 1. Follow the published service information (SI) diagnostics for drive belt chirping. The diagnostic chart for the drive belt chirping will ask to inspect for a misaligned accessory drive pulley. Important Remove the top section of the radiator shroud and TCM/cover to gain access to check alignment and measure the power steering pulley on the power steering pump shaft. 2. Verify that the power steering pulley is properly pressed onto the power steering pump shaft. Refer to SI for the power steering pulley replacement. If the pulley needs to be realigned on the power steering pump shaft, follow the published SI procedures for the power steering pulley replacement. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 3363 3. If the noise was not fully eliminated by the procedure in step 2, the power steering pulley may be adjusted with an allowable maximum variance of 1.0 mm (0.039 in) to the front from the flush position on the shaft to assist in eliminating any remaining belt noise. Refer to graphic illustration number 1 and number 2. Ensure that the power steering pump pulley illustration number 1 is flush against the power steering pump shaft illustration number 2, with an allowable variance of 1.0 mm (0.039 in). 4. If the noise was not fully eliminated by the procedure in step 3, and there are no other concerns found, follow the published SI diagnostics for drive belt chirping. Then, if the vehicle was built prior to June 2004 go to step 5. If the vehicle was built after June 2004, go to step 6. 5. Vehicles Built Prior to June 2004: 1. Replace the A/C compressor/power steering pump mounting bracket with P/N 97362175. Refer to graphic illustration number 1. Follow the published SI procedures for the Air Conditioning (A/C) Compressor and Power Steering Pump Mounting Bracket Replacement. 2. With the new A/C compressor/power steering pump mounting bracket installed, reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2") drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear power steering bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 3364 6. Vehicles Built After June 2004: 1. Remove the front and rear power steering bracket bolts from the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. 2. Reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2 in) drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Dual Generator System New belts are not available for dual generator systems. If a belt chirp noise is occurring on a dual generator system, please complete a Field Product Report (FPR). The instructions for completing a FPR can be found in Service Bulletin Number 02-00-89-002G. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 3365 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle Engine Accessory Bracket: All Technical Service Bulletins Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle TECHNICAL Bulletin No.: 05-06-01-018B Date: February 09, 2011 Subject: Accessory Drive Belt Chirp, Squeal or Squeak Type Noise at Cold Idle (Replace A/C Compressor/Power Steering Pump Mounting Bracket or Enlarge Bracket Bolt Holes) Models: 2004-2010 Chevrolet Silverado 2006-2010 Chevrolet Express 2004-2010 GMC Sierra 2006-2010 GMC Savana Equipped with 6.6L Duramax(R) Diesel Engine (VINs D, 2 - RPOs LBZ, LLY, LMM) Supercede: This bulletin is being revised to add model years and RPOs. Please discard Corporate Bulletin Number 05-06-01-018A (Section 06 - Engine/Propulsion System). Condition Important It should be noted that a chirp type noise on engine shutdown is normal for a diesel engine due to higher engine compression and the rapid stopping of the crankshaft. No repairs should be attempted for this condition. Some customers may comment on an accessory drive belt chirp, squeal, or squeak type noise at idle, especially on a cold start. The noise may be reduced or go away after the engine warms up. Cause Some 2004/2005 Silverado or Sierra trucks, with a 6.6L LLY engine produced before June, 2004, may have an A/C compressor/power steering pump mounting bracket and power steering rear mounting bracket that are machined slightly out of specification, causing a misaligned power steering pump. If the power steering pump is misaligned, it will force the accessory drive belt to run farther inboard on the fan pulley. When the belt leaves the fan pulley, the belt will not align properly to the crankshaft pulley grooves and create a chirp or squeak type noise at the point of interference. Vehicles built after June 2004 will already have the new A/C compressor/power steering pump mounting bracket installed, but still may exhibit belt noise caused by the power steering pump rear mounting bracket. Correction Vehicles built prior to June 2004, replace the A/C compressor/power steering pump mounting bracket. Vehicles built after June 2004, enlarge the rear power steering pump bracket bolt holes. 1. Follow the published service information (SI) diagnostics for drive belt chirping. The diagnostic chart for the drive belt chirping will ask to inspect for a misaligned accessory drive pulley. Important Remove the top section of the radiator shroud and TCM/cover to gain access to check alignment and measure the power steering pulley on the power steering pump shaft. 2. Verify that the power steering pulley is properly pressed onto the power steering pump shaft. Refer to SI for the power steering pulley replacement. If the pulley needs to be realigned on the power steering pump shaft, follow the published SI procedures for the power steering pulley replacement. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 3371 3. If the noise was not fully eliminated by the procedure in step 2, the power steering pulley may be adjusted with an allowable maximum variance of 1.0 mm (0.039 in) to the front from the flush position on the shaft to assist in eliminating any remaining belt noise. Refer to graphic illustration number 1 and number 2. Ensure that the power steering pump pulley illustration number 1 is flush against the power steering pump shaft illustration number 2, with an allowable variance of 1.0 mm (0.039 in). 4. If the noise was not fully eliminated by the procedure in step 3, and there are no other concerns found, follow the published SI diagnostics for drive belt chirping. Then, if the vehicle was built prior to June 2004 go to step 5. If the vehicle was built after June 2004, go to step 6. 5. Vehicles Built Prior to June 2004: 1. Replace the A/C compressor/power steering pump mounting bracket with P/N 97362175. Refer to graphic illustration number 1. Follow the published SI procedures for the Air Conditioning (A/C) Compressor and Power Steering Pump Mounting Bracket Replacement. 2. With the new A/C compressor/power steering pump mounting bracket installed, reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2") drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear power steering bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 3372 6. Vehicles Built After June 2004: 1. Remove the front and rear power steering bracket bolts from the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. 2. Reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2 in) drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Dual Generator System New belts are not available for dual generator systems. If a belt chirp noise is occurring on a dual generator system, please complete a Field Product Report (FPR). The instructions for completing a FPR can be found in Service Bulletin Number 02-00-89-002G. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 3373 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Accessory Bracket: > 05-08-49-018A > May > 06 > Instruments - Service Tire Monitor Message is Displayed Low Tire Pressure Indicator: All Technical Service Bulletins Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Page 3384 Engine Accessory Bracket: Service and Repair Air Conditioning (A/C) Compressor and Power Steering Pump Mounting Bracket Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the drive belt. 3. If equipped, remove the auxiliary generator. 4. If equipped with dual generators, remove the bolt from the left side idler pulley (smooth pulley). 5. Remove the idler pulley. 6. Disconnect the air conditioning (A/C) compressor clutch electrical connector. 7. Disconnect the A/C cut out switch electrical connector. 8. Remove the A/C compressor bolts. 9. Move the A/C compressor with the hoses attached to the right side of the engine compartment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Page 3385 10. Remove the positive cable junction block to power steering pump bolt (1). 11. Secure the junction block out of the way. 12. Remove the rear power steering pump bracket bolts (1). 13. Remove the power steering pump front bracket bolt. 14. Move and secure the power steering pump out of the way. The hoses and battery cables can remain attach to pump. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Page 3386 15. Remove the A/C compressor and power steering pump bracket bolts. 16. Remove the A/C compressor and power steering pump bracket. Installation Procedure 1. Position the A/C compressor and power steering pump bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the A/C compressor and power steering pump bracket bolts. Tighten the bolts to 46 Nm (34 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Page 3387 3. Install the power steering pump and loosely install the front bracket bolt. 4. Install the rear power steering pump bracket bolts (1). Tighten the bolts to 50 Nm (37 ft. lbs.). 5. If equipped with dual generators, install the left side idler pulley and bolt. Tighten the bolt to 43 Nm (32 ft. lbs.). 6. Install the auxiliary generator. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Page 3388 7. Install the battery cable junction block and bolt (1). Tighten the bolt to 9 Nm (80 inch lbs.). 8. Position the A/C compressor. 9. Install the A/C compressor bolts. Tighten the bolts to 50 Nm (37 ft. lbs.). 10. Connect the A/C cut out switch electrical connector. 11. Connect the A/C clutch electrical connector. 12. Install the drive belt. 13. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Testing and Inspection Engine Mount: Testing and Inspection Engine Mount Inspection 1. Raise the vehicle. 2. Remove the oil pan skid plate. 3. Remove the engine protection shield. 4. Notice: Refer to Engine Mounting Notice in Service Precautions. Inspect for loose or missing bolts at the following locations: ^ Engine mount bracket to engine ^ Engine mount frame bracket to frame ^ Engine mount to engine mount bracket ^ Engine mount to engine mount frame bracket 5. Replace missing or loose bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Testing and Inspection > Page 3392 6. Notice: Refer to Engine Lifting Notice in Service Precautions. If the vehicle is 4WD, you will not be able to access the lifting points on the engine. In order to raise the engine, attach a chain to the front of the engine. Then follow the inspection steps. 7. If the vehicle is RWD, in order to raise the engine to inspect the left engine mount, use a suitable jack on the ground wire bolt bosses on the left side of the engine 8. If equipped with an automatic transmission, remove the bolt retaining the transmission oil cooler line bracket. 9. Move the transmission oil cooler lines aside. 10. In order to raise the engine to inspect the right engine mount, use a suitable jack on the ground wire bolt bosses on the right side of the engine 11. Perform the following in order to inspect the engine mounts: 1. Raise the engine to remove weight from the engine mount. 2. Place a slight tension on the rubber cushion. 3. Observe the engine mount for the following while raising the engine: ^ Heat check cracks covering the hard rubber surface ^ The rubber cushion is separated from the metal plate of the engine mount. ^ There is a split through the rubber cushion. 12. Replace the engine mount if any of the above conditions exist. 13. Notice: Refer to Fastener Notice in Service Precautions. Install the engine protection shield and bolts. Tighten the engine protection shield bolts to 20 Nm (15 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Testing and Inspection > Page 3393 14. Install the oil pan skid plate and bolts. Tighten the oil pan skid plate bolts to 20 Nm (15 ft. lbs.). 15. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Left Engine Mount: Service and Repair Left Engine Mount Replacement - Left Removal Procedure 1. If RWD vehicle, raise the vehicle to a height to work through the front wheelhouse opening. 2. If 4WD vehicle, raise the vehicle in order to remove the front tires and wheels and support with jackstands. 3. Remove the left front tire and wheel. 4. Remove the pushpins holding the left front fender wheelhouse inner panel (1). 5. Remove the wheelhouse inner panel. 6. Notice: Refer to Engine Mounting Notice in Service Precautions. Working through the wheelhouse opening remove the 3 bolts retaining the engine mount to the engine mount frame bracket. 7. Remove the oil pan skid plate, if equipped. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Left > Page 3396 8. Remove the engine protection shield from the vehicle, if equipped. 9. Notice: Refer to Engine Lifting Notice in Service Precautions. Important: When raising the engine only raise enough to separate the engine mount from the engine mount bracket. Raising any further will require removal of the fan shroud or the exhaust pipe. If RWD vehicle, using a suitable jack on the ground wire bolt bosses, raise the engine.Only raise the engine enough to separate the engine mount to engine mount bracket. 10. If 4WD vehicle, attach a chain to the front of the engine. Use accessible mounting bolts for the generator mounting bracket and the power steering pump mounting bracket. 11. Raise the engine with a suitable lifting device to remove the engine mount.Only raise the engine enough to separate the engine mount to engine mount bracket. 12. Remove the bolts holding the engine mount to the engine. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Left > Page 3397 13. Remove the 2 through-bolts for the engine mount frame bracket. 14. Remove the engine mount frame bracket. 15. Remove the engine mount. Installation Procedure 1. Position the engine mount frame bracket on the frame. Do not install the bolts. 2. Install the engine mount. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the 2 through-bolts. Tighten the through-bolts to 75 Nm (55 ft. lbs.). 4. Install the bolts holding the engine mount to the engine. Tighten the engine mount bolts to 58 Nm (43 ft. lbs.). 5. Lower the engine. 6. If 4WD vehicle remove the chain from the front of the engine. 7. If 4WD vehicle, install the generator mounting bracket and the power steering mount bracket bolt. Tighten the mounting bracket bolts to 50 Nm (37 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Left > Page 3398 8. Install the 3 bolts holding the engine mount to the engine mount frame bracket. Tighten the engine mount to engine mount frame bracket bolts to 65 Nm (48 ft. lbs.). 9. Install the engine protection shield and bolts. Tighten the engine protection shield bolts to 20 Nm (15 ft. lbs.). 10. Install the oil pan skid plate. Tighten the bolts to 20 Nm (15 ft. lbs.). 11. Install the left front tire and wheel. 12. Install the front fender wheelhouse inner panel 13. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Left > Page 3399 Engine Mount: Service and Repair Right Engine Mount Replacement - Right Removal Procedure 1. If RWD vehicle, raise the vehicle to a height to work through the front wheelhouse opening. 2. If 4WD vehicle, raise the vehicle in order to remove the front tires and wheels and support with jackstands. 3. Remove the right front tire and wheel, if necessary. 4. Remove the pushpins holding the right front fender wheelhouse inner panel (1). 5. Remove the wheelhouse inner panel. 6. Notice: Refer to Engine Mounting Notice in Service Precautions. Working through the wheelhouse opening remove the 3 bolts retaining the engine mount to the engine mount frame bracket. 7. Remove the oil pan skid plate, if equipped. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Left > Page 3400 8. Remove the engine protection shield from the vehicle, if equipped. 9. If RWD vehicle and equipped with an automatic transmission, remove the bracket bolt for the transmission oil cooler lines to the engine. 10. Move the transmission oil cooler lines aside. 11. Notice: Refer to Engine Lifting Notice in Service Precautions. Important: When raising the engine only raise enough to separate the engine mount from the engine mount bracket. Raising any further the fan shroud or the exhaust pipe will require removal. If RWD vehicle, using a suitable jack on the ground wire bolt bosses, raise the engine.Only raise the engine enough to separate the engine mount to engine mount bracket. 12. If 4WD vehicle, attach a chain to the front of the engine. Use accessible mounting bolts for the generator mounting bracket and the power steering pump mounting bracket. 13. Raise the engine with a suitable lifting device to remove the engine mount.Only raise the engine enough to separate the engine mount to engine mount bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Left > Page 3401 14. Remove the bolts holding the engine mount to the engine. 15. Remove the 2 through-bolts for the engine mount frame bracket. 16. Remove the engine mount frame bracket. 17. Remove the engine mount. Installation Procedure 1. Position the engine mount frame bracket on the frame. Do not install the bolts. 2. Install the engine mount. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the 2 through-bolts. Tighten the through-bolts to 75 Nm (55 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Left > Page 3402 4. Install the bolts holding the engine mount to the engine. Tighten the engine mount bolts to 58 Nm (43 ft. lbs.).. 5. Lower the engine. 6. If 4WD vehicle remove the chain from the front of the engine. 7. If 4WD vehicle, install the generator mounting bracket and the power steering mount bracket bolt. Tighten the mounting bracket bolts to 50 Nm (37 ft. lbs.). 8. Install the 3 bolts holding the engine mount to the engine mount frame bracket. Tighten the engine mount to engine mount frame bracket bolts to 65 Nm (48 ft. lbs.). 9. If RWD vehicle with an automatic transmission, install the bolt for the transmission oil cooler line bracket. Tighten the transmission oil cooler line bracket bolt to 9 Nm (80 inch lbs.). 10. Install the engine protection shield and bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Left > Page 3403 Tighten the engine protection shield bolts to 20 Nm (15 ft. lbs.). 11. Install the oil pan skid plate. Tighten the bolts to 20 Nm (15 ft. lbs.). 12. Install the right front tire and wheel. 13. Install the front fender wheelhouse inner panel. 14. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair Idler Pulley: Service and Repair Drive Belt Idler Pulley Replacement Removal Procedure 1. Remove the drive belt. 2. Remove the bolt (1) from the right side idler pulley. 3. Remove the idler pulley. 4. Remove the bolt (2) for the center idler pulley. 5. Remove the idler pulley. 6. If equipped with dual generators, remove the bolt from the left side idler pulley. 7. If equipped with dual generators, remove the idler pulley. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair > Page 3407 Install the right side idler pulley and bolt (1). Tighten the bolt to 50 Nm (37 ft. lbs.). 2. Install the center idler pulley and bolt (2). Tighten the bolt to 50 Nm (37 ft. lbs.). 3. If equipped with dual generators, install the left side idler pulley and bolt. Tighten the bolt to 50 Nm (37 ft. lbs.). 4. Install the drive belt. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure - Minimum- Hot - at idle ............................................................................................................................................................ 98 KPa (14 psi) Oil Pressure - Minimum - 1800 RPM .......................................................................................................................................................... 294 KPa (42 psi) Oil Relief Valve Opening Pressure .............................................................................................................................................................. 441 KPa (64 psi) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 3412 Engine Oil Pressure: Testing and Inspection Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 3413 Steps 1 - 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 3414 Step 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator and Tube Replacement Removal Procedure 1. Remove the oil level indicator. 2. Remove the exhaust manifold. 3. Remove the starter motor. 4. Remove the oil level indicator tube bolt at the fuel injection control module bracket. 5. Remove the oil level indicator tube and O-ring seals. 6. Remove and discard the O-ring seals. Installation Procedure 1. Install NEW O-ring seals onto the oil level indicator tube. 2. Lightly lubricate the O-ring seals with engine oil. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair > Page 3418 3. Install the oil level indicator tube. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the oil level indicator tube bolt at the fuel injection control module bracket. Tighten the bolt to 21 Nm (15 ft. lbs.). 5. Install the starter motor. 6. Install the exhaust manifold. 7. Install the oil level indicator. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Diesel Engine - Greater Than Expected Oil Consumption Engine Oil: Technical Service Bulletins Diesel Engine - Greater Than Expected Oil Consumption Bulletin No.: 02-06-01-027A Date: May 17, 2005 INFORMATION Subject: Information on Higher Than Expected Oil Consumption Models: 2001-2006 Chevrolet Silverado 2500-3500 Series Models 2006 Chevrolet Express 2500-3500 Series Models 2001-2006 GMC Sierra 2500-3500 Series Models 2006 GMC Savana 2500-3500 Series Models 2003-2006 Chevrolet Kodiak C4500-C5500 Series Models 2003-2006 GMC Topkick C4500-C5500 Series Models with 6.6L Duramax(TM) Diesel Engine (VINs 1, 2 - RPOs LB7, LLY) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 02-06-01-027 )Section 06 - Engine/Propulsion System). Information on Engine Oil Consumption Guidelines for the 6.6L Duramax Diesel Engine. All engines require oil to lubricate and protect the load bearing and internal moving parts from wear including cylinder walls, pistons and piston rings. When a piston moves down its cylinder, a thin film of oil is left on the cylinder wall. During the combustion process, part of this oil layer is consumed. As a result, varying rates of oil consumption are accepted as normal in all engines. Oil Consumption Oil usage has a direct relationship with the amount of fuel used. The harder an engine works, the more fuel and oil it will use. Therefore, oil usage as a factor of fuel usage is a more accurate indicator of acceptable oil consumption levels than vehicle mileage. The accepted rate of oil consumption for the 6.6L Duramax(TM) Diesel engine is 0.946 liter (1 qt) within 379 liters (100 gallons) of fuel used. This rate only applies to vehicles under warranty, maintained in accordance with the appropriate maintenance schedule, driven at legal speeds and within design intent of the vehicle. Many factors can affect an owner's concern with oil consumption. Driving habits and vehicle maintenance vary from owner to owner. Thoroughly evaluate each case before deciding whether the vehicle in question has abnormal engine oil consumption. Gasket and External Leaks Inspect the oil pans, engine covers, and the engine oil cooler for leakage. Inspect the turbocharger oil lines and fittings for signs of leakage. Inspect the turbocharger outlet pipe for signs of oil, indicating worn turbocharger shaft bushings or seals. Inspect for oil leakage into the engine coolant. Improper Reading of the Oil Level Indicator (Dipstick) The vehicle must be parked on a level surface to obtain accurate oil level readings. Verify that the dipstick tube is fully seated in the block. When checking the oil level, make sure the dipstick is wiped clean before taking an oil level reading and fully depress the dipstick until the shoulder bottoms out on the dipstick tube. The dipstick should be the proper part number for the engine/vehicle that is being checked. Not Waiting Long Enough After Running Engine to Check Oil Level The vehicle should be allowed to sit for at least 15 minutes, after the engine has been shut off, before taking an oil level reading to assure the oil has had enough time to drain back into the crankcase. In order to ensure accurate results, the temperature of the oil should be close to the same temperature as the last time the oil level was checked. Improper Oil Fill After an Oil Change Following an oil change, verify that the proper amount and type of oil was put in the engine and that the oil level on the dipstick is not above the full mark or below the add marks. Refer to the Owner's Manual or Service Manual for information on recommended oil quantity, viscosity, and quality. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Diesel Engine - Greater Than Expected Oil Consumption > Page 3423 Diesel engines require a CH-4 or CG-4 oil rating. High Speed or High RPM Driving Continuous driving at high speeds/high RPMs may increase oil consumption. Because this may not always be an everyday occurrence, it is hard to determine exactly how much the oil economy will be affected. Towing or Heavy Usage Towing a trailer or hauling additional weight will increase oil consumption. Large frontal area trailers will further increase the work required from the engine, especially at highway speeds, and thus increases the rate of oil consumption. PTO Operation Operation of a PTO will increase fuel and oil usage, as the PTO driven accessory uses engine power to operate. Crankcase Ventilation System Verify that the positive crankcase ventilation (PCV) system is operating properly. Blockages, restrictions or damage to the PCV system can result in increased oil use. Oil Dilution from Condensation On vehicles that are usually driven short distances, less than 8 km (5 mi), especially in colder weather, condensation generated from cold engine operation may not get hot enough to evaporate out of the oil. When this occurs, the dipstick may indicate that the oil level is over-full. Subsequent driving on a trip of sufficient length to enable normal engine operating temperature for 30 minutes or more, in order to vaporize excess moisture, may give the customer the impression of excessive oil consumption. Engine Temperature If an engine is run at overheated temperatures (see Owner's Manual or Service Manual) for more than brief periods, oil will oxidize at a faster than normal rate. In addition, gaskets may distort, piston rings may stick, and excessive wear may result. verify that all cooling system components are in proper working order. Engine Wear Piston scuffing, excessive piston-to-wall clearance, tapered or out of round cylinders, worn, damaged or improperly installed valve guides, seals and piston rings will all cause an increase in oil consumption. Measurement of Oil Consumption Engines require a period of time to BREAK IN so that moving parts are properly seated. Therefore, oil economy should not be tested until the vehicle has accumulated at least 8000 km (5000 mi) and the oil has been changed for the first time. During initial engine break-in periods before the first oil change, oil consumption may exceed 1.9 liters (2 quarts) or more per 379 liters (100 gallons) of fuel used. 1. Verify that the engine has no external leaks. Repair as necessary. 2. Begin oil consumption test after next regularly scheduled oil and filter change. Oil changes should not be performed during the test. 3. Verify that the engine is at normal operating temperature (see Owner's Manual or Service Manual). 4. Park the vehicle on a level surface. 5. Wait at least 15 minutes, after the engine is shut off, before checking the oil level to make sure that most of the oil has had time to drain back into the crankcase. 6. Verify that the oil level is at, but not above, the full mark on the dipstick and that the proper viscosity and quality oil are being used as recommended in the Owner's Manual. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Diesel Engine - Greater Than Expected Oil Consumption > Page 3424 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Diesel Engine - Greater Than Expected Oil Consumption > Page 3425 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Diesel Engine - Greater Than Expected Oil Consumption > Page 3426 7. Dealer should record the vehicle mileage, date and engine hours at the start of the test on the Oil Consumption Worksheet shown. 8. Ask the customer to verify and record the date, odometer, oil level, fuel added, and engine hours, each time the vehicle is fueled, following steps 3-5 and return the vehicle to the dealership if the oil level is found at or below the add mark, 0.946 liter (1 qt) low, if possible. The dealer will add oil to return the oil level to full. If the oil level remains above the add mark, the customer should continue to operate the vehicle and verify the engine oil level until either the oil level drops to or below the add mark or at least 4800 km (3000 mi) has accumulated since the test began before returning to the dealership for a final evaluation. 9. If the final evaluation shows that the engine uses more than 0.946 liter (1 qt) in 379 liters (100 gallons) of fuel used, follow the published symptom diagnostics as described in the appropriate Service Manual. If the oil consumption test shows that the engine uses less than 0.946 liter (1 qt) in 379 liters (100 gallons) of fuel used, explain to the customer that their engine meets the guidelines for oil consumption. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................ 9.5L (10.0 Qt) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 3429 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ................................................................ CI-4, CH-4 Grade ............................................................... ....................................................................................................................................... 15W-40 (preferred) Above 0° C (32° F) ............................................................................................................ ........................................................... 30W, 15W-40 (preferred) Below 0° C (32° F) .......................... .............................................................................................................................................................. ........... 10W-30 Below -18° C (0° F) .................................................................................................... .............................................................................................. 10W-30 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 3430 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. 2. Place a suitable container under the oil pan to drain the oil into. 3. Remove the oil drain plug. 4. Drain the engine oil. 5. Remove the oil filter. 6. Inspect to ensure the engine oil filter gasket is removed. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 3431 1. Lubricate the oil filter seal with clean engine oil. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil filter. Tighten the filter after contact plus 1 to 11⁄4 turn. 3. Install the oil pan drain plug. Tighten the plug to 84 Nm (62 ft. lbs.). 4. Lower the vehicle. 5. Fill the engine with the proper capacity and quality of engine oil. Refer to Capacities - Approximate Fluid in Maintenance and Lubrication. 6. Operate the engine, check for oil leaks, and normal oil pressure. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Technical Service Bulletins > Customer Interest for Oil Cooler: > 02-06-01-023F > Mar > 08 > Engine - Oil Leaks From The Oil Cooler Oil Cooler: Customer Interest Engine - Oil Leaks From The Oil Cooler TECHNICAL Bulletin No.: 02-06-01-023F Date: March 31, 2008 Subject: Oil Leak at Oil Cooler to Engine Block Mating Surface (Replace O-rings, Apply Sealant) Models: 2001-2005 Chevrolet Silverado 2500/3500 Series Pickup Models 2003-2005 Chevrolet Kodiak C4500/5500 Series Models 2001-2005 GMC Sierra 2500/3500 Series Pickup Models 2003-2005 GMC TopKick C4500/5500 Series Models with 6.6L Duramax(R) Diesel Engine (VINs 1, 2 - RPOs LB7, LLY) Supercede: This bulletin is being revised to change the part number and update the Warranty information. Please discard Corporate Bulletin Number 02-06-01-023E (Section 06 - Engine/Propulsion System). Condition Some customers may comment on oil leaks at the engine oil cooler. Cause Minor imperfections in the engine block machined surfaces at the oil cooler interface may allow oil seepage past the oil cooler 0-rings. Correction 1. Inspect for other oil leaks that may be perceived as an oil cooler leak. An oil leak from one of the main bearing cap side bolts may appear to be coming from the oil cooler. 2. If the oil cooler is leaking oil remove the oil cooler from the engine. Use care to remove only the five bolts that hold the oil cooler to the engine block. Refer to the Engine Mechanical sub-section in the appropriate Service Manual. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Technical Service Bulletins > Customer Interest for Oil Cooler: > 02-06-01-023F > Mar > 08 > Engine - Oil Leaks From The Oil Cooler > Page 3440 Apply sealer to this area 0-rings 3. Remove the 0-rings from the oil cooler and discard the 0-rings. 4. Clean the mating surfaces of the engine block and the oil cooler. 5. Install new 0-rings (2) to the oil cooler. 6. Apply sealant(1), P/N 88861417(in Canada, use P/N88861418), to the oil cooler as shown. Do not apply sealant to the 0-ring grooves on the oil cooler. 7. Install the oil cooler to the engine. Refer to the Engine Mechanical sub-section in the appropriate Service Manual. 8. The maximum working time of this sealant is 20 minutes. The sealant will be fully cured in 24 hours. The assembly may be filled with engine oil immediately after applying the sealant and torquing the bolts. The engine can be started after 2 hours of cure time. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Cooler: > 02-06-01-023F > Mar > 08 > Engine - Oil Leaks From The Oil Cooler Oil Cooler: All Technical Service Bulletins Engine - Oil Leaks From The Oil Cooler TECHNICAL Bulletin No.: 02-06-01-023F Date: March 31, 2008 Subject: Oil Leak at Oil Cooler to Engine Block Mating Surface (Replace O-rings, Apply Sealant) Models: 2001-2005 Chevrolet Silverado 2500/3500 Series Pickup Models 2003-2005 Chevrolet Kodiak C4500/5500 Series Models 2001-2005 GMC Sierra 2500/3500 Series Pickup Models 2003-2005 GMC TopKick C4500/5500 Series Models with 6.6L Duramax(R) Diesel Engine (VINs 1, 2 - RPOs LB7, LLY) Supercede: This bulletin is being revised to change the part number and update the Warranty information. Please discard Corporate Bulletin Number 02-06-01-023E (Section 06 - Engine/Propulsion System). Condition Some customers may comment on oil leaks at the engine oil cooler. Cause Minor imperfections in the engine block machined surfaces at the oil cooler interface may allow oil seepage past the oil cooler 0-rings. Correction 1. Inspect for other oil leaks that may be perceived as an oil cooler leak. An oil leak from one of the main bearing cap side bolts may appear to be coming from the oil cooler. 2. If the oil cooler is leaking oil remove the oil cooler from the engine. Use care to remove only the five bolts that hold the oil cooler to the engine block. Refer to the Engine Mechanical sub-section in the appropriate Service Manual. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Cooler: > 02-06-01-023F > Mar > 08 > Engine - Oil Leaks From The Oil Cooler > Page 3446 Apply sealer to this area 0-rings 3. Remove the 0-rings from the oil cooler and discard the 0-rings. 4. Clean the mating surfaces of the engine block and the oil cooler. 5. Install new 0-rings (2) to the oil cooler. 6. Apply sealant(1), P/N 88861417(in Canada, use P/N88861418), to the oil cooler as shown. Do not apply sealant to the 0-ring grooves on the oil cooler. 7. Install the oil cooler to the engine. Refer to the Engine Mechanical sub-section in the appropriate Service Manual. 8. The maximum working time of this sealant is 20 minutes. The sealant will be fully cured in 24 hours. The assembly may be filled with engine oil immediately after applying the sealant and torquing the bolts. The engine can be started after 2 hours of cure time. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement Oil Cooler: Service and Repair Engine Oil Cooler Hose/Pipe Replacement Engine Oil Cooler Hose/Pipe Replacement Removal Procedure The optional oil cooler is either an integral part of the radiator or a separate unit placed in front of the radiator. The cooler lines and hoses are serviceable. 1. Disengage the plastic caps from the quick connect fittings. Pull the caps back along the pipe. 2. Hold one leg of the retaining clip. 3. Using a small pick-type tool or bent screwdriver, gently pry the other end of the retaining clip from the quick connect fitting. 4. Rotate the retaining clip out of the quick connect fitting. Remove the retaining clip completely. 5. Discard the OLD retaining clip. 6. If equipped with a 6.0L engine, perform the following: 1. Open the oil cooler hose clip located on the lower fan shroud. 2. Remove the oil cooler hoses from the clip. 3. Gently pull the oil cooler pipe fittings straight out from the radiator quick connect fittings. 4. Raise and suitably support the vehicle. 7. Remove the exhaust manifold pipe nuts. 8. Reposition the pipe out of the way. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 3449 9. If equipped with a 8.1L engine, perform the following: 1. Remove the oil cooler hoses from the clip. 2. Gently pull the oil cooler pipe fittings straight out from the radiator quick connect fittings. 3. Raise and suitably support the vehicle. 10. If equipped, remove the engine shield bolts. 11. Remove the engine shield. 12. If equipped with a 6.0L engine, perform the following: 1. Remove the oil cooler hose bracket bolt (1). 2. Remove the oil cooler hose adapter bolts (2). 3. Remove the oil cooler hose assembly and gasket. Discard the gasket. 4. Inspect the fittings, connectors and cooler hoses for damage or distortion. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 3450 13. If equipped with a 8.1L engine, perform the following: 1. Remove the oil cooler hose bracket bolt. 2. Disconnect the quick connect fittings (1) at the engine. 3. Remove the oil cooler hose assembly. Discard the gasket. 4. Inspect the fittings, connectors and cooler hoses for damage or distortion. Installation Procedure 1. Important: A distinct snap should be heard when assembling the tube ends of the hose assembly to quick connectors. To ensure the tube is fully inserted into the connector, check by giving the tube a forceful pull. If equipped with a 8.1L engine, perform the following: 1. Remove the oil cooler hose assembly. 2. Connect the quick connect fittings (1) at the engine. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the oil cooler hose bracket bolt. Tighten the bolt to 50 Nm (37 ft. lbs.). 2. If equipped with a 6.0L engine, perform the following: 1. Install the oil cooler hose assembly and a new gasket. 2. Install the oil cooler hose adapter bolts (2). Tighten the bolts to 12 Nm (106 inch lbs.). 3. Install the oil cooler hose bracket bolt (1). Tighten the bolt to 25 Nm (18 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 3451 3. If equipped, install the engine shield. 4. Install the engine shield bolts. Tighten the bolts to 20 Nm (15 ft. lbs.). 5. Do not install the new retaining clip onto the fitting by pushing on the clip. 6. Important: Failure to properly install the retaining clip could cause the cooler line to come loose and cause damage to the engine. Install the NEW retaining clip into the quick connect fitting by using your thumb and forefinger. Insert the new retaining clip into one of the three fitting recesses. Ensure that the retaining clip is engaged in all 3 slots. 7. With one end of the retaining clip engaged in the connector fitting slot, use your thumb in order to rotate the retaining clip around the connector fitting, until the retaining clip snaps into place. 8. Ensure that the 3 retaining clip ears are seen from inside the fitting and that the retaining clip moves freely in the fitting slots. 9. Install a new retaining clip into the remaining quick connect fitting. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 3452 10. Install the pipe to the exhaust manifold. 11. Install the exhaust manifold pipe nuts. Tighten the nuts to 50 Nm (37 ft. lbs.). 12. Lower the vehicle. 13. If equipped with a 6.0L engine, perform the following: 1. Install the oil cooler hoses to the hose clip on the fan shroud. 2. Snap the oil cooler hose clip shut. 14. Important: ^ Ensure the oil cooler line being installed has a plastic cap on the end that connects to the quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new cap. Install the cap onto the cooler line prior cooler line installation. ^ Do not use the plastic cap in order to install the cooler line into the fitting. If equipped with a 8.1L engine perform the following: 3. Install the oil cooler hoses to the clip. 4. Install the oil cooler lines to the radiator. Install the cooler line straight into the quick connect fitting. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. 5. Pull back sharply on the cooler line in order to ensure that the cooler line is installed in the quick connect fitting. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 3453 15. Important: Do not manually depress the retaining clip when installing the plastic cap. Snap the plastic cap onto the quick connect fitting. 16. Ensure that the plastic cap is fully seated against the fitting. 17. Ensure that no gap is present between the cap and the fitting. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 3454 Oil Cooler: Service and Repair Engine Oil Cooler Pipe/Hose Quick Connect Fitting Engine Oil Cooler Pipe/Hose Quick Connect Fitting Removal Procedure 1. Disengage the plastic caps from the quick connect fittings. Pull the caps back along the pipe. 2. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring. 3. Rotate the retaining ring around the quick connector until the retaining ring is out of position and can be completely removed.Discard the retaining rings. 4. Remove the engine oil cooler line from the quick connector fitting at the radiator.Pull the lines straight out from the connectors. 5. Clean all of the components in a suitable solvent, and dry them with compressed air. 6. Inspect the fittings, the connectors, the cooler lines, and the cooler for damage, distortion, or restriction. Replace parts as necessary. Installation Procedure 1. Important: When performing the following procedure, do not reuse the old retaining rings. Replace the old retaining rings with new ones. Do not install the new retaining ring onto the fitting by pushing the retaining ring down over the fitting. Install a new retaining ring into each quick connector fitting. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 3455 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connector. 3. Rotate the retaining ring around the connector until the retaining ring is positioned with all 3 ears through the 3 slots. 4. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots. 5. Install the engine oil cooler line into the quick connector fitting until a click is heard or felt.Pull back on the engine oil cooler lines to ensure a proper connection. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 3456 6. Important: Do not manually depress the retaining clip when installing the plastic cap. Snap the plastic cap onto the quick connect fitting. 7. Ensure that the plastic cap is fully seated against the fitting. 8. Ensure that no gap is present between the cap and the fitting. 9. Inspect and fill the engine oil to the proper level. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 3457 Oil Cooler: Service and Repair Oil Filter Adapter and Oil Cooler Assembly Replacement Oil Filter Adapter and Oil Cooler Assembly Replacement Removal Procedure 1. Drain the engine coolant and the engine block. 2. If equipped, remove the oil pan skid plate bolts and plate. 3. If the vehicle is a 2-wheel drive (2WD), remove the crossmember bolts and crossmember. 4. If the vehicle is a 4-wheel drive (4WD), remove the crossmember bolts and crossmember. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 3458 5. Remove the oil filter. 6. Remove the left front tire. 7. Remove the left wheelhouse inner panel. 8. Remove the water pump outlet pipe nuts from the coolant pipe. 9. Remove the engine wiring harness retainer from the inner stud. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 3459 10. Remove the engine coolant pipe. 11. Remove and discard the coolant pipe O-ring. 12. Remove the oil cooler adapter nuts from the flywheel housing. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 3460 13. Remove the oil cooler adapter bolts from the oil filter adapter/oil cooler. 14. Remove the oil cooler adapter. 15. Remove the oil filter adapter/oil cooler bolts. 16. Remove the oil filter adapter/oil cooler. 17. Remove and discard the oil filter adapter/oil cooler O-ring seals. 18. If required, clean and inspect the oil filter adapter/oil cooler. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 3461 1. Install NEW O-rings (2) to the oil filter adapter/oil cooler. 2. Lubricate the O-rings with engine oil. 3. Apply sealer GM P/N 97720043 (Canadian P/N 88901148) or equivalent to the O-ring sealing area (1). 4. Install the oil filter adapter/oil cooler. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil filter adapter/oil cooler bolts. Tighten the bolts to 25 Nm (18 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 3462 6. Install the oil cooler adapter. 7. Install the oil cooler adapter bolts to the oil filter adapter/oil cooler. Tighten the bolts to 21 Nm (15 ft. lbs.). 8. Install the oil cooler adapter nuts to the flywheel housing. Tighten the nuts to 25 Nm (18 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 3463 9. Install a NEW coolant pipe O-ring. 10. Lubricate the O-ring with clean engine coolant. Do not use oil or grease. 11. Install the engine coolant pipe. 12. Install the engine wiring harness retainer to the inner stud. 13. Install the water pump outlet pipe nuts to the coolant pipe. 4Tighten the nuts to 25 Nm (18 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 3464 14. Install the oil filter. 15. If the vehicle is a 4WD, install the crossmember and bolts. Tighten the bolts to 100 Nm (74 ft. lbs.). 16. If the vehicle is a 2WD, install the crossmember and bolts. Tighten the bolts to 100 Nm (74 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 3465 17. If equipped, install the oil pan skid plate and bolts. Tighten the bolts to 20 Nm (15 ft. lbs.). 18. Install the left fender wheelhouse inner panel. 19. Install the left front tire. 20. Fill the cooling system. 21. Inspect the engine oil level and add as necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Filler / Breather Cap > Component Information > Service and Repair Engine Oil Filler / Breather Cap: Service and Repair Oil Fill Tube Replacement Removal Procedure 1. Remove the oil fill tube bolts. 2. Remove the oil fill tube. 3. Remove and discard the oil fill tube O-ring seal. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Filler / Breather Cap > Component Information > Service and Repair > Page 3469 1. Install a NEW O-ring seal onto the oil fill tube. 2. Install the oil fill tube. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the oil fill tube bolts. Tighten the bolts to 21 Nm (15 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 3474 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. 2. Place a suitable container under the oil pan to drain the oil into. 3. Remove the oil drain plug. 4. Drain the engine oil. 5. Remove the oil filter. 6. Inspect to ensure the engine oil filter gasket is removed. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 3475 1. Lubricate the oil filter seal with clean engine oil. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil filter. Tighten the filter after contact plus 1 to 11⁄4 turn. 3. Install the oil pan drain plug. Tighten the plug to 84 Nm (62 ft. lbs.). 4. Lower the vehicle. 5. Fill the engine with the proper capacity and quality of engine oil. Refer to Capacities - Approximate Fluid in Maintenance and Lubrication. 6. Operate the engine, check for oil leaks, and normal oil pressure. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair Oil Filter Adapter: Service and Repair Oil Filter Adapter and Oil Cooler Assembly Replacement Removal Procedure 1. Drain the engine coolant and the engine block. 2. If equipped, remove the oil pan skid plate bolts and plate. 3. If the vehicle is a 2-wheel drive (2WD), remove the crossmember bolts and crossmember. 4. If the vehicle is a 4-wheel drive (4WD), remove the crossmember bolts and crossmember. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 3479 5. Remove the oil filter. 6. Remove the left front tire. 7. Remove the left wheelhouse inner panel. 8. Remove the water pump outlet pipe nuts from the coolant pipe. 9. Remove the engine wiring harness retainer from the inner stud. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 3480 10. Remove the engine coolant pipe. 11. Remove and discard the coolant pipe O-ring. 12. Remove the oil cooler adapter nuts from the flywheel housing. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 3481 13. Remove the oil cooler adapter bolts from the oil filter adapter/oil cooler. 14. Remove the oil cooler adapter. 15. Remove the oil filter adapter/oil cooler bolts. 16. Remove the oil filter adapter/oil cooler. 17. Remove and discard the oil filter adapter/oil cooler O-ring seals. 18. If required, clean and inspect the oil filter adapter/oil cooler. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 3482 1. Install NEW O-rings (2) to the oil filter adapter/oil cooler. 2. Lubricate the O-rings with engine oil. 3. Apply sealer GM P/N 97720043 (Canadian P/N 88901148) or equivalent to the O-ring sealing area (1). 4. Install the oil filter adapter/oil cooler. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil filter adapter/oil cooler bolts. Tighten the bolts to 25 Nm (18 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 3483 6. Install the oil cooler adapter. 7. Install the oil cooler adapter bolts to the oil filter adapter/oil cooler. Tighten the bolts to 21 Nm (15 ft. lbs.). 8. Install the oil cooler adapter nuts to the flywheel housing. Tighten the nuts to 25 Nm (18 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 3484 9. Install a NEW coolant pipe O-ring. 10. Lubricate the O-ring with clean engine coolant. Do not use oil or grease. 11. Install the engine coolant pipe. 12. Install the engine wiring harness retainer to the inner stud. 13. Install the water pump outlet pipe nuts to the coolant pipe. 4Tighten the nuts to 25 Nm (18 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 3485 14. Install the oil filter. 15. If the vehicle is a 4WD, install the crossmember and bolts. Tighten the bolts to 100 Nm (74 ft. lbs.). 16. If the vehicle is a 2WD, install the crossmember and bolts. Tighten the bolts to 100 Nm (74 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 3486 17. If equipped, install the oil pan skid plate and bolts. Tighten the bolts to 20 Nm (15 ft. lbs.). 18. Install the left fender wheelhouse inner panel. 19. Install the left front tire. 20. Fill the cooling system. 21. Inspect the engine oil level and add as necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Service and Repair Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Remove the lower oil pan. 2. Remove the oil level sensor clip (3). 3. Remove the oil level sensor bolt (2) and sensor (1). Installation Procedure Important: When routing the oil level sensor wire, ensure that the wire is routed along the side of the oil pan. 1. Install the oil level sensor (1) and bolt (2). Tighten the bolt to 9 Nm (80 inch lbs.). 2. Install the oil level sensor clip (3). 3. Install the lower oil pan. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor For ECM > Component Information > Locations Oil Level Sensor For ECM: Locations Left Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor For ECM > Component Information > Locations > Page 3493 Left Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor For ECM > Component Information > Locations > Page 3494 Engine Oil Level Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Turbocharger > Component Information > Technical Service Bulletins > Engine - Turbocharger Lubrication Issues Oil Line: Technical Service Bulletins Engine - Turbocharger Lubrication Issues INFORMATION Bulletin No.: 03-06-93-001D Date: October 09, 2008 Subject: Diagnostic Information on Turbocharger Malfunction Due to Lack of Engine Oil for LBZ, LB7, LLY or LMM Duramax(TM) Diesel Engine Models: 2001-2009 Chevrolet Silverado 2003-2009 Chevrolet Kodiak C4500-C5500 Series 2006-2009 Chevrolet Express 2001-2009 GMC Sierra 2003-2009 GMC TopKick C4500-C5500 Series 2006-2009 GMC Savana with 6.6L Duramax(TM) V8 Diesel Engine (VINs D, 1, 2, 6 RPOs LBZ, LB7, LLY, LMM) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 03-06-93-001C (Section 06 - Engine/Propulsion System). Notice: Before installing a new turbocharger, clean any debris or excessive oil from the charge air cooler and intake system in order to prevent damage to the new turbocharger or an engine overspeed condition. Spun Camshaft Bearing If a turbocharger performance concern is thought to be caused from a deficiency of engine oil, the camshaft bearing should be checked. The number 4 camshaft bearing bore feeds the turbocharger engine oil supply hose. If this camshaft bearing spins in the bore, the turbocharger will be deprived of engine oil. This will cause a performance concern with the turbocharger. Incorrect diagnosis of this condition will result in a repeat performance concern with the turbocharger. Camshaft Bearing Inspection If the turbocharger has to be replaced, perform the following procedure in order to verify the condition of the number 4 camshaft bearing before installing a new turbocharger. 1. Remove the turbocharger. Refer to Service Information (SI) procedures for Turbocharger Replacement. 2. Remove the turbocharger oil supply hose. 3. Visually inspect for correct alignment of the number 4 camshaft bearing oil hole (Refer to illustration callout 4) through the turbocharger oil supply hole in the block (Refer to illustration callout 1). The camshaft journal oil groove (Refer to illustration callout 3) should be visible through the camshaft bearing oil hole (Refer to illustration callout 4). 4. Turn the engine over by hand a 1/2 turn. The camshaft journal oil groove (Refer to illustration callout 3) should still be visible through the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Turbocharger > Component Information > Technical Service Bulletins > Engine - Turbocharger Lubrication Issues > Page 3499 camshaft bearing oil hole (Refer to illustration callout 4) as the engine is turned. 5. If the camshaft bearing (Refer to illustration callout 2) has spun, the camshaft bearing oil hole (Refer to illustration callout 4) will either not be visible at all or it will be misaligned with the turbocharger oil supply hole during the inspection procedure. In the event of a spun camshaft bearing, the engine must be replaced. Restricted Turbocharger Oil Supply Hose If a lack of oil is suspected, the turbocharger oil supply hose should also be checked for damage. The turbocharger oil feed line is a high pressure plastic tube that is protected by a stainless steel braided covering. If it is twisted at all or bent too far during turbocharger removal, the plastic line may fold and kink. The kink may cause an oil flow restriction. If the plastic pipe does kink, it will not return back to its normal size and shape. The damage may not be obvious upon inspection because the braided steel covering will hide the deformity. LB7 Turbocharger Replacement During turbocharger removal on the 6.6L LB7 engine, the turbocharger oil feed line can be pulled directly away from the turbocharger body in a perpendicular fashion. Care must be taken to avoid excessive bending of the line. LBZ, LLY or LMM Turbocharger Replacement During repairs on the 6.6L LBZ, LLY or LMM engine, the EGR cooler does not allow enough perpendicular movement of the line to clear the turbocharger for removal. However, the line can be pushed straight forward of the turbocharger with less risk of kinking the line. Assistance may be required to keep the lines clear of the turbocharger during removal or installation. Notice: Do not twist the turbocharger oil supply line. Twisting of the line will result in the collapse and deformation of the plastic line, restricting oil flow and causing turbocharger performance concerns. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Turbocharger > Component Information > Technical Service Bulletins > Page 3500 Oil Line: Service and Repair Turbocharger Oil Supply Hose Replacement Removal Procedure 1. Remove the turbocharger. 2. Remove the turbocharger oil feed pipe bolt. 3. Remove the oil feed pipe and washer. Installation Procedure 1. Important: Lubricate the NEW washer with diesel fuel before installing. Position the oil feed pipe and a NEW washer into place. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Turbocharger > Component Information > Technical Service Bulletins > Page 3501 2. Install the oil feed pipe bolt. Tighten the bolt to 34 Nm (25 ft. lbs.). 3. Install the turbocharger. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Bolts/Nuts - Lower .................................................................................................................. ........................................................ 10 Nm (89 lb in) Oil Pan Bolt - Upper ......................................... ............................................................................................................................................ 20 Nm (15 lb ft) Oil Pan Skid Plate Bolt ................................................................................................................ ................................................................. 20 Nm (15 lb ft) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Lower Oil Pan: Service and Repair Lower Oil Pan Replacement - Lower ^ Tools Required J 37228 Seal Cutter Removal Procedure 1. Raise and suitably support the vehicle. 2. Place a suitable container under the engine in order to drain the oil. 3. Remove the oil drain plug. 4. Drain the engine oil. 5. Remove the oil pan skid plate bolts and plate, if equipped. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Lower > Page 3507 6. If equipped with a 2-Wheel Drive (2WD) vehicle, remove the crossmember bolts and crossmember. 7. If equipped with a 4-Wheel Drive (4WD) vehicle, remove the crossmember bolts and crossmember. 8. Disconnect the oil level sensor electrical connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Lower > Page 3508 9. Remove the lower oil pan bolts/nuts. Important: DO NOT damage the sealing surfaces when separating the lower oil pan from the upper oil pan. 10. Separate the lower oil pan from the upper oil pan using J 37228. 11. Remove the lower oil pan. 12. If necessary, clean and inspect the lower oil pan. Installation Procedure 1. Apply a 2-3 mm (0.79-0.118 inch) by 0.5-1.5 mm (0.02-0.06 inch) wide bead of sealant GM P/N 97720043 (Canadian P/N 88901148), or equivalent to the lower oil pan mating surface. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Lower > Page 3509 2. Install the lower oil pan. 3. Install the lower oil pan bolts/nuts. 4. Notice: Refer to Fastener Notice in Service Precautions. Tighten the oil pan bolts/nuts in the sequence shown. Tighten the bolts/nuts to 10 Nm (89 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Lower > Page 3510 5. Connect the oil level sensor electrical connector. 6. If equipped with a 2WD, install the crossmember and bolts. Tighten the bolts to 100 Nm (74 ft. lbs.). 7. If equipped with a 4WD, install the crossmember and bolts. Tighten the bolts to 100 Nm (74 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Lower > Page 3511 8. Install the oil pan skid plate and bolts, if equipped. Tighten the bolts to 20 Nm (15 ft. lbs.). 9. Install NEW engine oil and a oil filter. 10. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Lower > Page 3512 Oil Pan: Service and Repair Upper Oil Pan Replacement - Upper ^ Tools Required J 37228 Seal Cutter Removal Procedure 1. Remove the oil level indicator. 2. Remove the oil level indicator tube bolt from the fuel injection control module bracket. 3. If vehicle is a 4-wheel drive (4WD), remove the front differential carrier. 4. If vehicle is a 2-wheel drive (2WD), disconnect the relay rod from the pitman arm and idler arm. 5. Remove the lower oil pan. 6. Remove the engine flywheel. 7. Remove the battery cable bracket bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Lower > Page 3513 8. Remove the battery cable bracket nut. 9. Remove the two flywheel housing to upper oil pan bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Lower > Page 3514 10. Remove the upper oil pan bolts and any brackets. Mark the bolt location of the bracket. 11. Separate the upper oil pan from the engine block using J 37228. 12. Remove the upper oil pan. The oil level indicator tube needs to be removed while lowering the upper oil pan. 13. If required, clean and inspect the upper oil pan. Installation Procedure 1. Apply a 2-3 mm (0.79-0.118 inch) wide by 0.5-1.5 mm (0.02-0.06 inch) bead of sealant GM P/N 97720043 (Canadian P/N 88901148), or equivalent to the upper oil pan mating surfaces. 2. Apply a 2-3 mm (0.79-0.118 inch) wide by 0.5-1.5 mm (0.02-0.06 inch) bead of sealant GM P/N 97720043 (Canadian P/N 88901148), or equivalent to the flywheel housing sealing surface. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Lower > Page 3515 3. Install the upper oil pan to the engine block. Ensure the oil level indicator tube is installed into the upper oil pan. 4. Notice: Refer to Fastener Notice in Service Precautions. Install any brackets and the upper oil pan bolts in the sequence shown. Tighten the bolts to 20 Nm (15 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Lower > Page 3516 5. Install the two flywheel housing to upper oil pan bolts. Tighten the bolts to 50 Nm (37 ft. lbs.). 6. Install the battery cable bracket bolts. Tighten the bolts to 12 Nm (106 inch lbs.). 7. Install the battery cable bracket nut. Tighten the nut to 8 Nm (71 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Lower > Page 3517 8. Install the engine flywheel. 9. Install the lower oil pan. 10. If vehicle is a 4WD, install the front differential carrier. 11. If vehicle is a 2WD, Connect the relay rod to the pitman arm and idler arm. 12. Lower the vehicle. 13. Install the oil level indicator tube bolt to the fuel injection control module bracket. Tighten the bolt to 21 Nm (15 ft. lbs.). 14. Install the oil level indicator. 15. Fill the engine with oil. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Left Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3521 Left Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3522 Oil Pressure Sender: Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the left wheelhouse inner panel. Important: Clean the area around the sensor. Do not allow debris to enter the engine. 2. Disconnect the oil pressure sensor electrical connector. 3. Using J 41712, remove the oil pressure sensor (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Service and Repair > Page 3526 Installation Procedure 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 41712, install the oil pressure sensor (1). Tighten the sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector. 4. Install the left wheelhouse inner panel. 5. Check and add engine oil if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure - Minimum- Hot - at idle ............................................................................................................................................................ 98 KPa (14 psi) Oil Pressure - Minimum - 1800 RPM .......................................................................................................................................................... 294 KPa (42 psi) Oil Relief Valve Opening Pressure .............................................................................................................................................................. 441 KPa (64 psi) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 3531 Engine Oil Pressure: Testing and Inspection Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 3532 Steps 1 - 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 3533 Step 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Engine - Intake Manifold Inspection/Replacement Intake Manifold: Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement INFORMATION Bulletin No.: 00-06-01-026C Date: February 03, 2010 Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine). When replacing an engine due to internal damage, extreme care should be taken when transferring the intake manifold to the new Goodwrench service engine long block. Internal damage may result in the potential discharge of internal engine component debris in the intake manifold via broken pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the engine, the technician should carefully inspect all of the cylinder head intake ports to see if the valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently bent, internal engine component debris will be present to varying degrees in the intake port of the cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold should be replaced. This replacement is required due to the complex inlet runner and plenum configuration of most of the intake manifolds, making thorough and complete component cleaning difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake manifold removed from an engine with deposits of internal engine component debris may result in the ingestion of any remaining debris into the new Goodwrench service engine. This may cause damage or potential failure of the new service engine. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 3538 Intake Manifold: Specifications Left Right Intake Manifold Bolts/Nuts ................................................................................................................... .................................................... 25 Nm (18 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Cover Replacement Intake Manifold: Service and Repair Intake Manifold Cover Replacement Intake Manifold Cover Replacement Removal Procedure 1. Loosen the intake manifold cover clamp (1) at the resonator. 2. Loosen the intake manifold cover bolt (2). 3. Remove the intake manifold cover. Installation Procedure 1. Install the intake manifold cover. 2. Tighten the intake manifold cover bolt (2) until snug. 3. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Cover Replacement > Page 3541 Tighten the intake manifold cover clamp (1) at the resonator. Tighten the clamp to 6 Nm (53 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Cover Replacement > Page 3542 Intake Manifold: Service and Repair Intake Manifold Replacement - Center Intake Manifold Replacement - Center Removal Procedure 1. Remove the Exhaust Gas Recirculation (EGR) valve cooler tube. 2. Remove the intake manifold tube. 3. Remove and discard the 2 intake manifold tube gaskets. 4. Remove the turbocharger. 5. Remove the center intake manifold bolts/nuts. 6. Pull-up the center intake manifold in order to remove. 7. Remove and discard the gaskets. 8. Clean the center intake manifold in cleaning solvent and air dry. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Cover Replacement > Page 3543 Installation Procedure 1. Install NEW center intake manifold gaskets. 2. Install the center intake manifold. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the center intake manifold bolts/nuts. Tighten the bolts/nuts to 10 Nm (89 inch lbs.). 4. Install the turbocharger. 5. Install 2 NEW O-rings onto the intake manifold tube. 6. Lubricate the O-rings with clean engine oil to aid in the installation. 7. Install the intake manifold tube. 8. Install the EGR valve cooler tube. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Cover Replacement > Page 3544 Intake Manifold: Service and Repair Intake Manifold Replacement - Left Intake Manifold Replacement - Left Removal Procedure 1. Remove the center intake manifold. 2. Remove the left fuel rail. 3. Remove the intake manifold bolts/nuts. 4. Important: The intake manifold uses sealer. Pry at the area by the fuel rail bolt holes in order to avoid damage to the sealing surface. Remove the intake manifold. 5. To prevent entry of debris into the cylinder head, tape the openings. 6. If required, clean and inspect the intake manifold. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Cover Replacement > Page 3545 1. Apply a 2-3 mm (1/8 inch) wide, by 0.5-1.5 mm (1/16 inch) high bead of sealant, GM P/N 97720043 (Canadian P/N 88901148), or equivalent to the intake manifold. 2. Install the intake manifold. 3. Install the intake manifold bolts/nuts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Cover Replacement > Page 3546 Left 4. Notice: Refer to Fastener Notice in Service Precautions. Tighten the intake manifold bolts/nuts in the sequence shown. Tighten the bolts/nuts to 21 Nm (15 ft. lbs.). 5. Install the left fuel rail. 6. Install the center intake manifold. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Cover Replacement > Page 3547 Intake Manifold: Service and Repair Intake Manifold Replacement - Right Intake Manifold Replacement - Right Removal Procedure 1. Remove the center intake manifold. 2. Remove the right fuel rail. 3. Remove the intake manifold bolts/nuts. 4. Important: The intake manifold uses sealer. Pry at the area by the fuel rail bolt holes in order to avoid damage to the sealing surfaces. Remove the intake manifold. 5. To prevent entry of debris in the cylinder head tape the openings. 6. If required, clean and inspect the intake manifold. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Cover Replacement > Page 3548 1. Apply a 2-3 mm (1/8 inch) wide, by 0.5-1.5 mm (1/16 inch) high bead of sealant GM P/N 97720043 (Canadian P/N 88901148), or equivalent to the intake manifold. 2. Install the intake manifold. 3. Install the intake manifold bolts/nuts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Cover Replacement > Page 3549 Right 4. Notice: Refer to Fastener Notice in Service Precautions. Tighten the intake manifold bolts/nuts in the sequence shown. Tighten the bolts/nuts to 21 Nm (15 ft. lbs.). 5. Install the right fuel rail. 6. Install the center intake manifold. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Cover Replacement > Page 3550 Intake Manifold: Service and Repair Intake Manifold Tube Replacement Intake Manifold Tube Replacement Removal Procedure 1. Remove the intake manifold cover. 2. Remove the air cleaner outlet duct. 3. Loosen the charged air cooler outlet duct to intake hose clamp. 4. Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting. Remove the charged air cooler outlet duct from the intake. 5. If necessary, remove the tie strap from the electrical harness. 6. Reposition the harness clip from the intake manifold tube, as needed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Cover Replacement > Page 3551 7. Remove the air inlet tube to intake manifold tube bolt and nut. 8. Remove the air inlet tube nuts. 9. Remove the air inlet tube. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Cover Replacement > Page 3552 10. If necessary, remove the intake manifold tube. 11. If necessary, remove and discard the 2 O-ring seals from the tube. 12. Clean the gasket surfaces of the exhaust gas recirculation (EGR) cooler tube, intake manifold tube and inlet tube. Installation Procedure 1. If necessary, install NEW O-ring seals onto the tube. 2. If necessary, install the intake manifold tube. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Cover Replacement > Page 3553 3. Install the air inlet tube and NEW gaskets. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the air inlet tube nuts. Tighten the nuts to 25 Nm (18 ft. lbs.). 5. Install the air inlet tube to intake manifold tube bolt and nut. Tighten the bolt/nut to 10 Nm (89 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Cover Replacement > Page 3554 6. If necessary, install a NEW tie strap over the electrical harness. 7. Important: Lubricate the end of the duct prior to installation. Install the charged air cooler outlet duct to the intake. 8. Tighten the charged air cooler outlet duct to intake hose clamp. Tighten the clamp to 6 Nm (53 inch lbs.). 9. Install the air cleaner outlet duct. 10. Install the intake manifold cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal Replacement ^ Tools Required J 44641 Crankshaft Rear Oil Seal Remover - J 44642 Crankshaft Rear Oil Seal Installer Removal Procedure 1. Remove the flywheel. 2. Clean the area around the crankshaft rear oil seal. 3. Install J 44641 to the crankshaft rear oil seal. 4. Remove the crankshaft rear oil seal using J 44641. Installation Procedure 1. Ensure that the crankshaft is free of oil and dirt. 2. Clean the seal bore in the flywheel housing. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 3559 3. Position the crankshaft rear oil seal onto the crankshaft. Important: J 44642 must be fully secured to the crankshaft to ensure proper seal depth. 4. Install J 44642 to the crankshaft. 5. Press the crankshaft rear oil seal into position using J 44642, the tool will bottom out when the seal reaches the proper depth. 6. Remove J 44642. 7. Install the flywheel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Diesel Engine - Reman Engine Head Gasket Thickness Cylinder Head Gasket: Technical Service Bulletins Diesel Engine - Reman Engine Head Gasket Thickness INFORMATION Bulletin No.: 07-06-01-009A Date: November 02, 2009 Subject: 6.6L LB7, LLY Duramax(R) Diesel Engine Cylinder Head Gasket Missing Thickness Grade Markings - Inspect Block for Stampings Models: 2001-2005 Chevrolet Silverado 2003-2005 Chevrolet Kodiak C4500/5500 Series 2001-2005 GMC Sierra 2003-2005 GMC TopKick C4500/5500 Series with 6.6L Duramax(R) Diesel Engine (VINs D, 1, 2 - RPOs LB7, LLY) Supercede: This bulletin is being revised to remove the Warranty Information and update the Parts Information. Please discard Corporate Bulletin Number 07-06-01-009 (Section 06 - Engine/Engine Mechanical). A small number of remanufactured engines were built using oversized bore or milled deck gaskets that do not have any thickness grade identification markings. These engines may show up in any model year from 2001-2005 if the vehicle has received an engine replacement. Inspect the block for stampings (1) indicating cylinder overbore and a milled deck. The overbore gasket accommodates all cylinder bores from 0.010-0.030". All blocks that are milled are also over-bored. Crimped Construction Style Head Gasket First generation head gasket crimped construction (1). Riveted Construction Style Head Gasket Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Diesel Engine - Reman Engine Head Gasket Thickness > Page 3564 Second generation head gasket riveted construction (1). Important The gaskets with no thickness grade specifications will be of crimped construction as opposed to riveted construction. These gaskets require a higher torque specification than what is published in SI. Use the following torque specification when servicing an engine using a head gasket of crimped construction. Cylinder Head Bolt Torque Specification for Crimped Construction Head Gasket Refer to Cylinder Head Replacement in SI. Tighten the cylinder head bolts in the following steps using the sequence below: Tighten 1. Tighten the M12 bolts a first pass to 50 Nm (37 lb ft). 2. Tighten the M12 bolts a second pass to 80 Nm (59 lb ft). 3. Tighten the M12 bolts a third pass to 90 degrees, using Torque Angle Meter J 45059. 4. Tighten the M12 bolts a final pass to 75 degrees, using Torque Angle Meter J 45059. 5. Tighten the M8 bolts to 25 Nm (18 lb ft). Crimped Cylinder Head Gasket Parts Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Diesel Engine - Reman Engine Head Gasket Thickness > Page 3565 Cylinder Head Gasket: Technical Service Bulletins Diesel Engine - New Cyl. Head Gasket/Head Bolt Torque INFORMATION Bulletin No.: 06-06-01-006C Date: October 30, 2009 Subject: Information on 6.6L LBZ, LB7, LLY Duramax(R) Diesel Engine Cylinder Head Gasket Design Change - New Head Gasket Part Numbers and Head Bolt Torque Specifications Models: 2001-2006 Chevrolet Silverado 2003-2006 Chevrolet Kodiak C4500/5500 Series 2006 Chevrolet Express 2001-2006 GMC Sierra 2003-2006 GMC TopKick C4500/5500 Series 2006 GMC Savana with 6.6L Duramax(R) Diesel Engine (VINs D, 1, 2 - RPOs LBZ, LB7, LLY) Supercede: This bulletin is being revised to remove the Warranty Information. Please discard Corporate Bulletin Number 06-06-01-006B (Section 06 - Engine/Propulsion System). Important If a cylinder head gasket is found to be absent of thickness grade markings, refer to Service Bulletin 07-06-01-009 for gasket identification. A mid-year design change was made to the head gasket of the 2006 Duramax Diesel engine in December, 2005. This second generation gasket will service all 2001-2006 vehicles, including those with engines built using first generation gaskets. The second generation gasket will require a lower head bolt torque angle specification as well as special cleaning methods of the gasket surfaces. Gasket Identification The second generation gasket can be visually identified by its riveted construction, as opposed to the crimped design of the first generation gasket. Second Generation Head Gasket (Riveted Construction) Refer to the above illustration number (1) showing riveted construction. First Generation Head Gasket (Crimped Construction) Refer to the above illustration number (1) showing crimped construction. Special Cleaning Requirements For 2001-2006 vehicles produced with the first generation head gasket, special attention must be given to the cleaning of the engine block and cylinder head surfaces when servicing with a second generation gasket. The crimped areas (1) on the first generation gasket may, over time, allow corrosion buildup where they contact the block and cylinder head surfaces. The second generation gasket has raised ribs that seal at these crimped areas (1). A special cleaning procedure is required to ensure proper sealing. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Diesel Engine - Reman Engine Head Gasket Thickness > Page 3566 Cleaning Procedure 1. Remove the old head gasket using service manual procedures. Save the gasket for reference until the repair is completed. 2. Place clean rags in the cylinder bores and pushrod openings in order to keep out debris. 3. Use the J-28410 or equivalent to carefully clean the gasket sealing surface of large sealing or corrosion matter. When scraping, take care not to scratch or gouge the metal surfaces. Do not push the debris into oil, coolant, and combustion openings or bolt holes. 4. Inspect the gasket sealing surfaces for corrosion, especially in the areas that were in contact with the crimped tabs of the first generation head gasket. If corrosion is present, continue with the rest of the steps in this procedure for proper cleaning. If the sealing surface is sufficiently clean and smooth, use the revised torque specification listed towards the end of this bulletin and continue with published service manual procedures to complete the repair. 5. For surfaces that have corrosion or pitting, wrap a piece of flat steel (4"x 2" or larger) with 600 grit wet grade sand paper. Using Moisture Displacing Lubricant, P/N 88862629 (in Canada, use 89020803) or equivalent, wet sand the block surface to remove any remaining gasket material or corrosion. Do not use any paper coarser than 600 grit. Notice - Do not use any power type sanding devices. - Do not use a wire brush or wheel to clean gasket surfaces. - Do not use chemical cleaning agents on gasket surfaces. 6. Take care to keep the sanding block parallel to the block surface and evenly sand the sealing surface. Some areas of corrosion will still show a stain. Do not attempt to wet sand these areas down to a shiny metal surface. 7. Change the sanding paper when it becomes clogged. Carefully and frequently wipe the surface, using a clean cloth each time, to prevent sanding debris from building up and contaminating the oil and coolant cavities. 8. Clean the bolt threads and holes and remove the rags from the bore cavities and pushrod openings. 9. Repeat the above cleaning procedure on the cylinder head gasket surface. 10. Clean the engine block and cylinder head gasket surfaces with Brake Parts Cleaner, P/N 88862650 (in Canada, use 88901247) or equivalent, to remove any traces of oil or debris. 11. Using the revised head bolt torque specification below, reassemble the engine with NEW M12 cylinder head bolts according to service manual procedures. Torque Specification Change The second design head gasket requires a lower torque angle specification for the M12 bolts than the torque required by the first generation gasket. The M8 bolt torque remains the same for both designs. The M12 bolts on engines using the second generation head gasket should be torqued using the angular tightening method to the following specifications: Important SI will be updated with the revised torque specification. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Diesel Engine - Reman Engine Head Gasket Thickness > Page 3567 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair Crankshaft Front Oil Seal Replacement ^ Tools Required J 44644 Crankshaft Front Oil Seal Remover - J 44645 Crankshaft Front Oil Seal Installer Removal Procedure 1. Remove the crankshaft balancer. 2. Install J 44644 to the crankshaft front oil seal. The jaws of the J 44644 fit into the inner sleeve. 3. Using J 44644, remove the crankshaft front oil seal. Installation Procedure 1. Clean the front crankshaft seal bore and the crankshaft. 2. Lubricate the crankshaft sealing surface with clean engine oil. 3. Place the crankshaft front oil seal onto the crankshaft. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 3571 4. Install J 44645 to the crankshaft. 5. Press the crankshaft front oil seal onto the crankshaft using J 44645 until the tool bottoms out. 6. Remove J 44645. 7. Measure the distance between the end of the crankshaft and the oil seal. 8. The service measurement is 43.45-44.05 mm (1.7106-1.7342 inch). 9. Install the crankshaft balancer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement ^ Tools Required J 26999 Compression Gage - J 26999-20 Compression Gage Adapter - J 44646 Valve Spring Compressor - J 44640 Valve Stem Seal Installer Removal Procedure 1. Remove the upper and lower fan shroud. 2. Remove the valve rocker arm shaft, valve bridges, and pushrods for the cylinder head being serviced. 3. Remove the glow plug for the cylinder requiring service. 4. In order to apply shop air to the cylinders use the following procedures to modify J 26999-20 (1) and J 26999 (2): 1. Remove the valve core from J 26999-20 to allow air to flow. 2. Remove the quick connect fitting from J 26999. 3. Adapt the quick connect fitting in order to use for shop air. 4. Connect the quick connect fitting to J 26999-20. 5. Important: Rotate the cylinder to be serviced to the bottom of the stroke. This is to ensure that the engine does not rotate when the compressed air is applied to the cylinder being serviced. Install J 26999-20 into the glow plug hole for the cylinder being serviced. 6. Apply compressed air to hold the valves in place. If the compressed air is released, the valves can drop into the cylinder. 7. Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. Install J 44646 to the rocker arm bosses on the cylinder head. J 44646 should be installed in the rocker arm boss next to the cylinder being serviced. The pivot pin can be removed from the stand to allow the stand to be installed. The lever has different locating holes for the pivot pin depending on available clearance. The lever is also notched for different locations of the compressor. 8. Using J 44646 compress the valve spring. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 3575 9. Remove the valve keys (1) from the valve stem. 10. Carefully release the valve spring tension. 11. Remove the valve spring upper seat (2) and the valve spring (3). 12. Remove the valve stem oil seal (4). 13. Remove the valve spring lower seat (5). 14. Continue removing the remaining valve stem seals for the cylinder using the above procedure. Installation Procedure 1. Notice: Air pressure should remain applied to the cylinder for installation. Install the valve spring lower seat. 2. Install the valve stem seal using J 44640. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 3576 3. Install the valve spring (3), the painted end of the valve spring goes toward the cylinder head. 4. Install the valve spring upper seat (2). 5. Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. Using J 44646 compress the valve spring. 6. Install the valve keys to the valve stem. 7. Notice: The valve stem keys must correctly seat in the valve spring cap. Engine damage may occur by not installing properly. Carefully release the valve spring pressure. Make sure the valve keys stay in place. 8. Continue to install the 3 remaining valve stem seals for the cylinder. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 3577 9. Release the compressed air holding the valves in place. 10. Remove J 26999-20 (1) from the glow plug hole. 11. Continue to replace the valve stem seals on the remaining cylinders using the above procedures. 12. Install the glow plug. 13. Install the valve rocker arm shaft, the valve bridges, and the push rods. 14. Install the upper and lower fan shroud. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Service and Repair Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Remove the lower oil pan. 2. Remove the oil level sensor clip (3). 3. Remove the oil level sensor bolt (2) and sensor (1). Installation Procedure Important: When routing the oil level sensor wire, ensure that the wire is routed along the side of the oil pan. 1. Install the oil level sensor (1) and bolt (2). Tighten the bolt to 9 Nm (80 inch lbs.). 2. Install the oil level sensor clip (3). 3. Install the lower oil pan. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor For ECM > Component Information > Locations Oil Level Sensor For ECM: Locations Left Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor For ECM > Component Information > Locations > Page 3585 Left Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor For ECM > Component Information > Locations > Page 3586 Engine Oil Level Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Left Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3590 Left Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3591 Oil Pressure Sender: Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the left wheelhouse inner panel. Important: Clean the area around the sensor. Do not allow debris to enter the engine. 2. Disconnect the oil pressure sensor electrical connector. 3. Using J 41712, remove the oil pressure sensor (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair > Page 3595 Installation Procedure 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 41712, install the oil pressure sensor (1). Tighten the sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector. 4. Install the left wheelhouse inner panel. 5. Check and add engine oil if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Engine front cover bolts ....................................................................................................................... ..................................................... 25 Nm (18 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3600 Timing Cover: Service and Repair Engine Front Cover Replacement ^ Tools Required J 37228 Seal Cutter Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the water pump. 3. Remove the crankshaft front oil seal. 4. Remove the right wheelhouse panel. 5. Disconnect the crankshaft position (CKP) sensor electrical connector. 6. Remove the CKP sensor bolt and sensor. 7. Remove the CKP sensor spacer bolts and spacer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3601 8. Remove and discard the O-rings from the sensor and the spacer. 9. Remove the upper oil pan to engine front cover bolts. 10. Remove the engine front cover bolts. 11. Separate the engine front cover from the cylinder block and upper oil pan using J 37228. 12. Important: Do not bend the turbocharger coolant pipe. Remove the engine front cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3602 13. If necessary, remove the pressure relief valve O-ring. 14. Clean and inspect the front cover. Installation Procedure 1. If necessary, install a NEW pressure relief valve O-ring. Notice: Refer to Fastener Notice in Service Precautions. 2. Lubricate the O-ring with engine oil. Tighten the valve to 39 Nm (29 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3603 3. Apply a 2-3 mm (1/8 inch) wide by 0.5-1.5 mm (1/16 inch) high, bead of sealant GM P/N 97720043 (Canadian P/N 88901148), or equivalent to the engine front cover sealing surface to the engine block. 4. Apply a 2-3 mm (1/8 inch) wide by 0.5-1.5 mm (1/16 inch) high, bead of sealant GM P/N 97720043 (Canadian P/N 88901148), or equivalent to the engine front cover sealing surface to the upper oil pan. 5. Install the engine front cover. 6. Install the engine front cover bolts. Tighten the bolts to 25 Nm (18 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3604 7. Install the upper oil pan to engine front cover bolts. Tighten the bolts to 21 Nm (15 ft. lbs.). 8. Install a NEW O-ring to the CKP sensor spacer. 9. Lubricate the O-ring with clean engine oil. Important: The crankshaft position sensor spacers are machined with different timing positions. However, if the crankshaft position sensor spacer requires replacement, replace with a grade “C” spacer. 10. Install the CKP sensor spacer and bolts. Tighten the bolts to 10 Nm (89 inch lbs.). 11. Install a NEW O-ring to the CKP sensor. 12. Lubricate the O-ring with clean engine oil. 13. Install the CKP sensor and bolt. Tighten the bolt to 10 Nm (89 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3605 14. Connect the CKP sensor electrical connector. 15. Install the right wheelhouse panel. 16. Install the crankshaft front oil seal. 17. Install the water pump. 18. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations FUEL SCHRADER VALVE The Fuel Schrader Valve is located on the right front of the engine, on the right upper valve rocker Arm cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information Not Supplied By The Manufacturer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Air Cleaner Fresh Air Duct/Hose: Customer Interest Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3623 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3624 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3625 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3626 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3627 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3628 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3629 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Air Cleaner Fresh Air Duct/Hose: All Technical Service Bulletins Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3635 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3636 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3637 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3638 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3639 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3640 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3641 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Page 3642 Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR CLEANER OUTLET DUCT REPLACEMENT REMOVAL PROCEDURE 1. Loosen the outlet duct clamps at the turbocharger and the mass air flow (MAF)/intake air temperature (IAT) sensor. 2. Remove the air cleaner outlet duct. INSTALLATION PROCEDURE IMPORTANT: The air cleaner outlet duct must be fully seated against the positive stop feature on the turbocharger inlet. 1. Install the air cleaner outlet duct. NOTE: Refer to Fastener Notice in Service Precautions. 2. Tighten the outlet duct clamps at the turbocharger and the MAF/IAT sensor. Tighten Tighten the clamps to 6 N.m (53 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Restriction Indicator > Component Information > Description and Operation Air Cleaner Restriction Indicator: Description and Operation AIR CLEANER RESTRICTION INDICATOR The air cleaner restriction indicator is located on the air cleaner housing. If the area inside of the clear section is green, no air filter service is required. If the area inside the clear section is orange and Change Air Filter appears, replace the air filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Air Filter Element: Customer Interest Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3654 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3655 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3656 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3657 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3658 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3659 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3660 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 3665 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Air Filter Element: All Technical Service Bulletins Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3671 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3672 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3673 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3674 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3675 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3676 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3677 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 3682 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 05-00-90-001 > Jan > 05 > Diesel Engine - IMPORTANT Correct Air Filter Usage Air Filter Element: All Technical Service Bulletins Diesel Engine - IMPORTANT Correct Air Filter Usage Bulletin No.: 05-00-90-001 Date: January 05, 2005 INFORMATION Subject: Information on the Proper Air Filter for the Duramax(R) Diesel Models: 2001-2005 Chevrolet Silverado 2001-2005 GMC Sierra with 6.6L Duramax(R) Diesel Engine (VINs 1, 2 - RPOs LB7, LLY) The Duramax(R) air filter, P/N 25332443, is specific to the diesel engine due to the operating characteristics of a turbo charged diesel engine. The turbo allows for a much greater air volume rate than a normal aspirated engine. The Duramax(R) diesel air filter is reinforced to eliminate damage from the increased airflow of the turbo. The reinforcement is visually identified by the five ribs of epoxy that lies across the pleats of the clean side of the filter. If the correct air filter is not used, the filter may collapse or be torn in a Duramax(R) application. This damage will allow dust and dirt to be ingested into the turbo and engine causing serious damage. This damage is usually identified at the turbo vanes as well as extreme wear in the cylinder walls of the engine. There is evidence of gasoline engine air filters being used in the Duaramax(R) application. The 8.1 gas air filter, P/N 25313349, will fit into the air box of the Duramax(R) diesel; however, it does not have the required reinforcement of the diesel air filter. The 8.1 liter gas engine air filter should never be used in a Duramax(R) diesel engine. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 05-00-90-001 > Jan > 05 > Diesel Engine - IMPORTANT Correct Air Filter Usage Air Filter Element: All Technical Service Bulletins Diesel Engine - IMPORTANT Correct Air Filter Usage Bulletin No.: 05-00-90-001 Date: January 05, 2005 INFORMATION Subject: Information on the Proper Air Filter for the Duramax(R) Diesel Models: 2001-2005 Chevrolet Silverado 2001-2005 GMC Sierra with 6.6L Duramax(R) Diesel Engine (VINs 1, 2 - RPOs LB7, LLY) The Duramax(R) air filter, P/N 25332443, is specific to the diesel engine due to the operating characteristics of a turbo charged diesel engine. The turbo allows for a much greater air volume rate than a normal aspirated engine. The Duramax(R) diesel air filter is reinforced to eliminate damage from the increased airflow of the turbo. The reinforcement is visually identified by the five ribs of epoxy that lies across the pleats of the clean side of the filter. If the correct air filter is not used, the filter may collapse or be torn in a Duramax(R) application. This damage will allow dust and dirt to be ingested into the turbo and engine causing serious damage. This damage is usually identified at the turbo vanes as well as extreme wear in the cylinder walls of the engine. There is evidence of gasoline engine air filters being used in the Duaramax(R) application. The 8.1 gas air filter, P/N 25313349, will fit into the air box of the Duramax(R) diesel; however, it does not have the required reinforcement of the diesel air filter. The 8.1 liter gas engine air filter should never be used in a Duramax(R) diesel engine. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 3692 Air Filter Element: Service Precautions NOTE: This information is contained within GM Bulletin 05-00-90-001 dated January 5, 2005. Subject: Information on the Proper Air Filter for the Duramax(R) Diesel Models: 2001-2005 Chevrolet Silverado and GMC Sierra with 6.6L Duramax(R) Diesel Engines (VINs 1, 2 - RPOs LB7, LLY) The Duramax(R) air filter. P/N 25332433, is specific to the diesel engine due to the operating characteristics of a turbocharged diesel engine. The turbo allows for a much greater air volume rate than a normally aspirated engine. The Duramax(R) diesel air filter is reinforced to eliminate damage from the increased airflow of the turbo. The reinforcement is visually identified by the five ribs of epoxy that lie across the pleats of the clean side of the filter. If the correct air filter is not used, the filter may collapse or be torn in a Duramax(R) application. This damage will allow dust and dirt to be ingested into the turbo and engine causing serious damage. This damage is usually identified at the turbo vanes as well as extreme wear in the cylinder walls of the engine. There is evidence of gasoline engine air filters being used in the Duramax(R) application. The 8.1 gas air filter, P/N 25313349 will fit into the air box of the Duramax(R) diesel; however, it does not have the required reinforcement of the diesel air filter. The 8.1 liter gas engine air filter should never be used in a Duramax(R) diesel engine. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 3693 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector (1). 2. Loosen the screws holding the air cleaner housing halves together. 3. Separate the housing halves and remove the air filter element. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 3694 1. Install the air filter element into the lower air cleaner housing. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the upper housing cover and tighten the screws. Tighten Tighten the screws to 4 N.m (35 lb in). 3. Connect the MAF/IAT sensor electrical connector (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Improved Fuel Filter Design Fuel Filter: Technical Service Bulletins Fuel System - Improved Fuel Filter Design INFORMATION Bulletin No.: 04-06-04-070B Date: March 02, 2009 Subject: Information on Improved Fuel Filter for 6.6L Duramax(TM) Diesel Engine Models: 2001-2009 Chevrolet Silverado 2003-2009 Chevrolet Kodiak 2006-2009 Chevrolet Express 2001-2009 GMC Sierra 2003-2009 GMC TopKick 2006-2009 GMC Sierra Equipped with 6.6L Duramax(TM) Diesel Engine (VINs 1, 2, D, 6 - RPOs LB7, LLY, LBZ, LMM) Supercede: This bulletin is being revised to provide additional information to the field on fuel filter applications for the Duramax diesel engine. Please discard Corporate Bulletin Number 04-06-04-070A (Section 06 - Engine/Propulsion System). Important: It is acceptable to use diesel fuel containing up to 5% biodiesel (B5). Higher concentration (i.e., greater than B5) biodiesel-containing fuels or the use of unmodified bio-oils blended into diesel fuel at any concentration is not recommended and could damage the fuel system and engine. Such damage would not be covered by your warranty. A revised fuel filter is released that will service all 2001-2009 Chevrolet and GMC C/K models and 2003-2009 Chevrolet and GMC C4500/5500 Series vehicles with the 6.6L Duramax(TM) Diesel. The new coalescer filter provides the following benefits / improvements over the existing dual pleat design: ^ 150-200% increase in service life, depending on contaminant type Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Improved Fuel Filter Design > Page 3699 ^ Improved fuel system protection with some premium diesel and B5 biodiesel blends ^ Equivalent coarse water droplet removal efficiency of previous design ^ Greatly improved removal of emulsified water - a major contributor to fuel system issues Proper fuel filter servicing and the use of clean diesel fuel that is free of water or contaminants are critical for the longevity of fuel system components of a modern direct injected diesel engine. Adherence to the fuel filter change interval will help to ensure that the Duramax fuel system will be protected from contaminants and that the engine will continue to operate as designed. Purchasing fuel from a high volume fuel retailer increases the chances that the fuel is fresh and of good quality. Parts Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Page 3700 Fuel Filter: Locations FUEL FILTER/HEATER ELEMENT HOUSING Fuel Filter/Heater Element Housing Water In Fuel Sensor The Fuel Filter/Heater Element Housing is located on the right engine rocker cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Page 3701 Fuel Filter: Description and Operation FUEL FILTER The fuel filter is located on the rocker cover. The paper filter element traps particles in the fuel that may damage the fuel injection system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly Fuel Filter: Service and Repair Fuel Filter Assembly FUEL FILTER ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Drain the fuel from the fuel filter. Refer to Water-in-Fuel Draining Procedure. 2. Reposition the fuel hose clamps. 3. Remove the fuel hoses. 4. Disconnect the fuel filter electrical connectors. 5. Remove the fuel filter bracket bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 3704 6. Remove the fuel filter assembly. 7. Remove the fuel filter bracket bolts and bracket from the fuel filter/heater element housing. 8. Remove the fuel filter from the fuel filter/heater element housing. 9. Inspect the fuel filter, replace if necessary. INSTALLATION PROCEDURE 1. Install the fuel filter to the fuel filter/heater element housing. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel filter bracket and bolts to the fuel filter/heater element housing. Tighten Tighten the bolts to 20 N.m (15 lb ft). 3. Install the fuel filter assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 3705 4. Install the fuel filter bracket bolts. Tighten Tighten the bolts to 20 N.m (15 lb ft). 5. Connect the fuel filter electrical connectors. 6. Install the fuel hoses. 7. Position the fuel hose clamps. 8. Prime the fuel system. Refer to Fuel System Priming. 9. Start the engine. If the engine stalls, repeat the above step. 10. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 3706 Fuel Filter: Service and Repair Fuel Filter Element FUEL FILTER REPLACEMENT REMOVAL PROCEDURE 1. Drain the fuel from the fuel filter. Refer to Water-in-Fuel Draining Procedure. 2. Reposition the fuel hose clamps. 3. Remove the fuel hoses. 4. Disconnect the fuel filter connectors. 5. Unscrew the fuel filter from the fuel filter adapter. 6. Remove the water-in-fuel sensor from the fuel filter. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 3707 1. Install the water-in-fuel sensor to the NEW fuel filter. IMPORTANT: Inspect the fuel heater element housing for contamination. Contamination on the fuel heater element housing may cause leakage at the fuel filter. Coat the fuel filter seal with clean engine oil. 2. Screw on the NEW fuel filter to the fuel filter adapter. 3. Connect the fuel filter connectors. 4. Install the fuel hoses. 5. Position the fuel hose clamps. 6. Prime the fuel system. Refer to Fuel System Priming. 7. Start the engine. If the engine stalls, repeat the above step. 8. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 3708 Fuel Filter: Service and Repair Fuel Filter Life Reset FUEL FILTER LIFE RESET This message will appear when a reset is performed either by using the steering wheel controls or the following manual procedure. For vehicles with steering wheel controls: 1. Reset the fuel filter monitor. 2. Press and hold the select button for five seconds while the "FUEL FILTER LIFE" message is displayed. This message will appear on the DIC for ten seconds. For vehicles without steering wheel controls, do the following: 1. Without pressing the pedals, turn the ignition key to the "ON" position without starting the engine. 2. Wait five seconds. 3. Completely press the brake and the accelerator pedals simultaneously and hold for ten seconds. The system is now reset. 4. Turn the ignition key off. The next time the engine is started, the message will no longer be displayed. Always reset the FUEL FILTER LIFE system after a fuel filter change. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 3709 Fuel Filter: Service and Repair Fuel System Priming FUEL SYSTEM PRIMING IMPORTANT: In order for the DURAMAX diesel engine fuel system to work properly, the fuel lines must be full of fuel and contain no air. If air gets into the fuel lines, it will be necessary to prime the fuel system to eliminate the air before operating the vehicle. Air could have entered to system in one of the following ways: - The vehicle ran out of fuel. - The filter was removed for service or replacement. - The fuel lines were removed or disconnected for servicing. - The fuel filter water drain cock was opened while the engine was running. If one or more of the above occurred, air has entered the fuel system and you will need to prime the system prior to operating the vehicle. 1. Prior to priming the engine, ensure that the following is complete: - There is fuel in the fuel tank. - The fuel filter has been installed and properly tightened. - The fuel lines are properly connected. - The fuel filter is cool to the touch. - Any dirt or debris is removed from the fuel filter head and vent valve. 2. Open the vent valve by turning the screw counterclockwise several full turns. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 3710 3. Operate the priming pump until a small amount of fuel seeps from the vent valve. allow the pump to return upwards between pumps. When fuel is present, the filter is full of fuel and the system should be primed. 4. Close the vent valve. 5. Clean any fuel which accumulated on the fuel filter. 6. Start the engine and allow it to idle for a few minutes. 7. Check the filter for leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications GThe minimum compression in any one cylinder is 2069 kPa (300 psi). There should not be more than 345 kPa (50 psi) difference between a suspect cylinder and the average compression of all 8 cylinders. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3714 Compression Check: Testing and Inspection Engine Compression Test ^ Tools Required J 26999 Compression Gage - J 26999-20 Compression Gage Adapter - J 43244 Relay Puller Pliers 1. Ensure that the vehicle's batteries are in good condition, and fully charged. 2. Operate the vehicle until the engine is at normal operating temperature. 3. Shut off engine. 4. Disable fuel delivery system, by removing the IGN B relay with J 43244. 5. Disconnect glow plug nut; remove all 8 glow plugs. All 8 glow plugs must be removed from the engine during each cylinder test to obtain valid test results. 6. Prior to taking a compression reading, verify the cranking speed is greater than 140 RPM. If the cranking speed is below 140 RPM, repair the slow cranking speed condition before continuing with the compression test. Refer to Engine Cranks Slowly in Engine Electrical. 7. Install the J 26999-20 in the glow plug hole for the cylinder that is being checked. 8. Notice: Do not add oil to any cylinder during a compression test as extensive engine damage may result. Connect the J 26999 to the J 26999-20. 9. Using the vehicle's starter motor, rotate or crank the engine for 6 compression strokes, puffs, for the cylinder being tested. 10. Observe the J 26999 and note the reading as the compression test is being performed. A normal cylinder reading will be indicated if compression builds up quickly and evenly to the specified level. An abnormal reading will be indicated if compression is low on the first compression stroke, starts increasing on the following compression strokes but does not reach the specified level. 11. Record the compression reading for the cylinder just tested. 12. Disconnect the J 26999 from the J 26999-20 and remove adapter from the glow plug hole. 13. Repeat steps 8 through 13 for all remaining cylinders. All 8 cylinders must be tested to obtain valid test results. Record the readings. 14. The minimum compression in any one cylinder is 2069 kPa (300 psi). There should not be more than 345 kPa (50 psi) difference between a suspect cylinder and the average compression of all 8 cylinders. ^ Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. ^ Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes but does not reach normal. ^ Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Fuel Temperature Sensor: Service and Repair FUEL RAIL TEMPERATURE (FRT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold cover. IMPORTANT: After removing the charged air cooler duct, cover the turbocharger openings with tape in order to prevent entry of objects. 2. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting. 3. Remove the charged air cooler inlet duct connector (4) from the turbocharger. 4. Disconnect the fuel temperature sensor electrical connector. 5. Remove the fuel temperature sensor. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 3718 1. Install the fuel temperature sensor. Tighten Tighten the sensor to 22 N.m (16 lb ft). 2. Connect the fuel temperature sensor electrical connector. 3. Remove the tape from the turbocharger openings. 4. Install the charged air cooler inlet duct connector (4) to the turbocharger. 5. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1). Tighten Tighten the clamp to 6 N.m (53 lb in). 6. Install the intake manifold cover. 7. Prime the fuel system. Refer to Fuel System Priming. 8. Start the engine. If the engine stalls, repeat the above step. 9. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 3719 Fuel Pressure Test Port: Locations FUEL SCHRADER VALVE The Fuel Schrader Valve is located on the right front of the engine, on the right upper valve rocker Arm cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolt ................................................................................................................................. ...................................................... 25 Nm (18 ft. lbs.) Water Pump Inlet Pipe Bolts ........................... .......................................................................................................................................... 25 Nm (18 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3723 Water Pump: Service and Repair Water Pump Replacement (6.6L (LLY) Engine) Removal Procedure 1. Remove the left wheelhouse inner panel. 2. Remove the thermostat housing crossover. 3. Remove the crankshaft balancer. 4. Remove the water pump to engine coolant pipe nuts. 5. Remove the engine wiring harness retainer from the inner stud. 6. Remove the water pump bolts. Note the location of the bolts. The bolts are three different lengths. 7. Remove the water pump. 8. Remove and discard the water pump O-ring and coolant pipe gasket. 9. If required, clean and inspect the water pump. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3724 Installation Procedure 1. Lubricate the water pump O-ring with engine oil. 2. Install the engine coolant pipe gasket and water pump O-ring. 3. Install the water pump. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the water pump bolts. Ensure the correct length bolt is used in the proper location. Tighten the bolts to 21 Nm (15 ft. lbs.). 5. Install the engine wiring harness retainer on the water pump outlet pipe inner stud. 6. Install the water pump to engine coolant pipe nuts. Tighten the nuts to 21 Nm (15 ft. lbs.). 7. Install the thermostat housing crossover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3725 8. Install the crankshaft balancer. 9. Install the left wheelhouse inner panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component Information > Service and Repair > Thermostat Bypass Pipes Replacement Thermostat Bypass Hose: Service and Repair Thermostat Bypass Pipes Replacement Thermostat Bypass Pipes Replacement (6.6L (LLY) Engine) Removal Procedure 1. Remove the thermostat housing. 2. Remove the bypass pipe from the thermostat housing. 3. Remove and discard the O-ring seals from the bypass pipe and the water pump. 4. Clean the sealing surfaces of the bypass pipe. 5. If required, clean and inspect the bypass pipe and thermostat housing. Installation Procedure 1. Install a NEW O-ring seal onto the bypass pipe. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component Information > Service and Repair > Thermostat Bypass Pipes Replacement > Page 3731 2. Install a NEW O-ring seal to the water pump. 3. Lubricate the O-ring seals with clean engine coolant. 4. Install the bypass pipe into the thermostat housing. 5. Install the thermostat housing. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component Information > Service and Repair > Thermostat Bypass Pipes Replacement > Page 3732 Thermostat Bypass Hose: Service and Repair Turbocharger Coolant Bypass Valve Replacement Turbocharger Coolant Bypass Valve Replacement (6.6L (LLY) Engine) Removal Procedure 1. Remove the intake manifold cover. 2. Drain the cooling system. 3. Reposition the coolant inlet hose clamp. 4. Disconnect the turbocharger coolant inlet hose from the turbocharger bypass valve. 5. Remove the turbocharger bypass valve and washer. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component Information > Service and Repair > Thermostat Bypass Pipes Replacement > Page 3733 1. Notice: Refer to Fastener Notice in Service Precautions. Install the turbocharger bypass valve and washer. Tighten the valve to 60 Nm (44 ft. lbs.). 2. Connect the turbocharger coolant inlet hose to the turbocharger bypass valve. 3. Position the coolant inlet hose clamp. 4. Fill the cooling system. 5. Install the intake manifold cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 3738 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 3739 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 3740 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 3741 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System ................................................................................................................................... ............................................... 23.0 liters (24.0 quarts) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 3744 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs first, if you add only DEX-COOL extended life coolant. A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will: ^ Give freezing protection down to -34°F (-37°C). ^ Give boiling protection up to 265°F (129°C). ^ Protect against rust and corrosion. ^ Help keep the proper engine temperature. ^ Let the warning lights and gages work as they should. NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle. WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't damage aluminum parts. If you use this coolant mixture, you don't need to add anything else. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. If you have to add coolant more than four times a year, check your cooling system. NOTICE: If you use the proper coolant, you do not have to add extra inhibitors or additives which claim to improve the system. These can be harmful. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Locations Left Side Of The Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Locations > Page 3748 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement Coolant Line/Hose: Service and Repair Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement (6.6L (LLY) Engine) Removal Procedure 1. Remove the intake manifold cover. 2. Remove the air cleaner outlet duct. 3. Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting. Loosen the charged air cooler outlet duct to intake hose clamp. 4. Remove the charged air cooler outlet duct from the intake. 5. Remove the tie strap from the electrical harness. 6. Reposition the engine harness from the air inlet tube. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 3753 7. Remove the air inlet tube nuts. 8. Remove the air inlet tube. 9. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 10. Reposition the Exhaust Gas Recirculation (EGR) coolant pipe hose clamp. 11. Remove the EGR coolant pipe hose. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 3754 12. Remove the EGR coolant pipe bolts. 13. Remove the EGR coolant pipe. 14. Remove and discard the coolant pipe O-ring seal. Installation Procedure 1. Install a NEW O-ring seal onto the coolant pipe. Lubricate the seal with engine coolant. 2. Install the EGR coolant pipe. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the EGR coolant pipe bolts. Tighten the bolts to 25 Nm (18 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 3755 4. Install the EGR coolant pipe hose. 5. Position the EGR coolant pipe hose clamp. 6. Connect the ECT sensor electrical connector. 7. Install the air inlet tube. 8. Install the air inlet tube nuts. Tighten the nuts to 25 Nm (18 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 3756 9. Position the engine harness to the air inlet tube. 10. Install a NEW tie strap. 11. Important: Lubricate the end of the duct prior to installation. Install the charged air cooler outlet duct to the intake. 12. Tighten the charged air cooler outlet duct to intake hose clamp. Tighten the clamp to 6 Nm (53 inch lbs.). 13. Install the air cleaner outlet duct. 14. Install the intake manifold cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 3757 Coolant Line/Hose: Service and Repair Turbocharger Coolant Hoses/Pipes Replacement Engine - Inlet Pipe Turbocharger Coolant Hoses/Pipes Replacement (6.6L (LLY) Engine - Inlet Pipe) Removal Procedure 1. Remove the intake manifold cover. 2. Drain the cooling system. 3. Important: After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1). Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting. 4. Remove the charged air cooler inlet duct connector (4) from the turbocharger. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 3758 5. Reposition the turbocharger coolant inlet hose clamp at the bypass valve. 6. Remove the turbocharger coolant inlet hose banjo bolt (1). 7. Remove the inlet hose washer and inlet line. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 3759 1. Install the inlet hose washer and inlet line. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the turbocharger coolant inlet hose banjo bolt (1). Tighten the bolt to 25 Nm (18 ft. lbs.). 3. Position the turbocharger coolant inlet hose clamp at the bypass valve. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 3760 4. Remove the tape from the turbocharger openings. 5. Important: Lubricate the end of the duct prior to installation. Install the charged air cooler inlet duct connector (4) to the turbocharger. 6. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1). Tighten the clamp to 6 Nm (53 inch lbs.). 7. Fill the cooling system. 8. Install the intake manifold cover Engine - Outlet Pipe Turbocharger Coolant Hoses/Pipes Replacement (6.6L (LLY) Engine - Outlet Pipe) Removal Procedure 1. Remove the intake manifold cover. 2. Drain the cooling system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 3761 3. Disconnect the negative battery cables. 4. Remove the air cleaner outlet duct. 5. Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damage. Loosen the hose by twisting. Loosen the charged air cooler outlet duct to intake hose clamp. 6. Remove the charged air cooler duct from the intake. 7. Remove the generator mounting bracket. 8. Remove the Exhaust Gas Recirculation (EGR) cooler tube. 9. Disconnect the fuel injection control module electrical connectors. 10. Remove the upper fuel injection control module fuel line bolt. 11. Remove and discard the washer from the banjo fitting. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 3762 12. Reposition the hose clamp at the bypass pipe. 13. Remove the turbocharger coolant outlet hose from the bypass pipe. 14. Reposition the turbocharger coolant outlet hose clamp. 15. Remove the turbocharger coolant outlet hose from the pipe on the turbocharger. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 3763 16. Remove the turbocharger coolant outlet pipe bolt and nut. 17. If necessary, remove the turbocharger. 18. If necessary, remove the coolant outlet pipe clip bolt (3) from the turbocharger. 19. If necessary, remove the coolant outlet pipe. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 3764 1. If necessary, install the coolant outlet pipe. 2. Notice: Refer to Fastener Notice in Service Precautions. If necessary, install the coolant outlet pipe clip bolt (3) to the turbocharger. Tighten the bolt to 9 Nm (80 inch lbs.). 3. If necessary, install the turbocharger. 4. Install the turbocharger coolant outlet pipe bolt and nut. Tighten the bolt/nut to 9 Nm (80 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 3765 5. Install the turbocharger coolant outlet hose to the pipe on the turbocharger. 6. Position the turbocharger coolant outlet hose clamp. 7. Install the turbocharger coolant outlet hose to the bypass pipe. 8. Position the hose clamp at the bypass pipe. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 3766 9. Install a NEW washer to the banjo fitting. 10. Install the upper fuel injection control module fuel line bolt. Tighten the bolt to 35 Nm (26 ft. lbs.). 11. Connect the fuel injection control module electrical connectors. 12. Install the EGR cooler tube. 13. Install the generator mounting bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 3767 14. Important: Lubricate the end of the duct prior to installation. Install the charged air cooler duct to the intake. 15. Tighten the charged air cooler outlet duct to intake hose clamp. Tighten the clamp to 6 Nm (53 inch lbs.). 16. Install the air cleaner outlet duct. 17. Connect the negative battery cables. 18. Fill the cooling system. 19. Install the intake manifold cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 3768 Coolant Line/Hose: Service and Repair Water Pump Outlet Pipe Replacement Water Pump Outlet Pipe Replacement (6.6L (LLY) Engine) Removal Procedure 1. Remove the water pump. 2. Remove the engine coolant pipe. 3. Remove and discard the coolant pipe O-ring seal. Installation Procedure 1. Install a NEW O-ring seal onto the coolant pipe. 2. Lubricate the O-ring seal with engine coolant. 3. Install the engine coolant pipe. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Coolant Hoses/Pipes Replacement > Page 3769 4. Install the water pump. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Outlet > Component Information > Service and Repair Coolant Outlet: Service and Repair Water Outlet Tube Replacement (6.6L (LLY) Engine) Removal Procedure 1. Remove the intake manifold cover. 2. Drain the cooling system. 3. Remove the radiator inlet hose from the water outlet tube. 4. Open the clip and remove the wiring harness branch from the bracket. 5. Remove the bolt and wiring harness bracket at the thermostat housing. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Outlet > Component Information > Service and Repair > Page 3773 6. Remove the main engine electrical harness connector bolts. 7. Disconnect the barometric sensor electrical connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Outlet > Component Information > Service and Repair > Page 3774 8. Disconnect the turbocharger vane position sensor electrical connector. 9. Remove the main electrical harness bracket bolts. 10. Remove the main electrical harness bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Outlet > Component Information > Service and Repair > Page 3775 11. Disconnect the turbocharger coolant inlet hose from the turbocharger bypass valve. 12. Remove the water outlet bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Outlet > Component Information > Service and Repair > Page 3776 13. Remove the water outlet. 14. Remove and discard the O-ring seal. Installation Procedure 1. Install a NEW O-ring seal to the water outlet. 2. Lubricate the O-ring seal with clean engine coolant. 3. Install the water outlet. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Outlet > Component Information > Service and Repair > Page 3777 4. Notice: Refer to Fastener Notice in Service Precautions. Install the water outlet bolts. Tighten the bolts to 21 Nm (15 ft. lbs.). 5. Connect the turbocharger coolant inlet hose to the turbocharger bypass valve. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Outlet > Component Information > Service and Repair > Page 3778 6. Install the main electrical harness bracket. 7. Install the main electrical harness bracket bolts. Tighten the bolts to 21 Nm (15 ft. lbs.). 8. Connect the turbocharger vane position sensor electrical connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Outlet > Component Information > Service and Repair > Page 3779 9. Connect the barometric sensor electrical connector. 10. Install the main engine electrical harness connector bolts. Tighten the bolts to 10 Nm (89 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Outlet > Component Information > Service and Repair > Page 3780 11. Install the wiring harness bracket and bolt to the thermostat housing. Tighten the bolt to 10 Nm (89 inch lbs.). 12. Install the wiring harness branch to the bracket and close the clip. 13. Install the radiator inlet hose to the water outlet tube. 14. Fill the cooling system. 15. Install the intake manifold cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Surge Tank Replacement Coolant Reservoir: Service and Repair Surge Tank Replacement Surge Tank Replacement Removal Procedure 1. Drain the cooling system. 2. Remove the air cleaner assembly. 3. Remove the surge tank overflow hose from the surge tank. 4. Disconnect the coolant level sensor electrical connector (3). 5. Reposition the surge tank inlet and outlet hose clamps. 6. If equipped with a 4.3 L, 4.8 L, 5.3 L, 6.0 L, or 8.1 L engine, remove the surge tank inlet (1) and outlet (2) hoses from the surge tank. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Surge Tank Replacement > Page 3785 7. Reposition the surge tank inlet hose clamp from the surge tank. 8. Remove the surge tank inlet hose (1) from the surge tank. 9. Reposition the surge tank outlet hose clamp from the surge tank. 10. Remove the surge tank outlet hose (2) from the surge tank. 11. Remove the bolt from the surge tank. 12. Remove the nut from the surge tank. 13. Remove the surge tank. Installation Procedure 1. Install the surge tank. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Surge Tank Replacement > Page 3786 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolt to the surge tank. Tighten the bolt to 9 Nm (80 inch lbs.). 3. Install the nut to the surge tank. Tighten the nut to 9 Nm (80 inch lbs.). 4. Install the surge tank outlet hose (2) to the surge tank. 5. Position the surge tank outlet hose clamp to the surge tank. 6. Install the surge tank inlet hose (1) to the surge tank. 7. Position the surge tank inlet hose clamp to the surge tank. 8. Connect the coolant level sensor electrical connector (3). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Surge Tank Replacement > Page 3787 9. Install the surge tank overflow hose. 10. Install the air cleaner assembly. 11. Fill the cooling system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Surge Tank Replacement > Page 3788 Coolant Reservoir: Service and Repair Surge Tank Hose/Pipe Replacement Surge Tank Hose/Pipe Replacement - Inlet Removal Procedure 1. Drain the cooling system. 2. Reposition the surge tank inlet hose clamp from the radiator. 3. Remove the surge tank inlet hose from the radiator. 4. Reposition the surge tank inlet hose clamp from the surge tank. 5. Remove the surge tank inlet hose (1) from the surge tank. Installation Procedure 1. Install the surge tank inlet hose (1) to the surge tank. 2. Position the surge tank inlet hose clamp to the surge tank. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Surge Tank Replacement > Page 3789 3. Install the surge tank inlet hose to the radiator. 4. Position the surge tank inlet hose clamp to the radiator. 5. Fill the cooling system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine Runs Hot Towing or Pulling Grades Fan Clutch: Customer Interest Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine Runs Hot Towing or Pulling Grades > Page 3799 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine Runs Hot Towing or Pulling Grades > Page 3800 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine Runs Hot Towing or Pulling Grades > Page 3801 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine Runs Hot Towing or Pulling Grades > Page 3802 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine Runs Hot Towing or Pulling Grades > Page 3803 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine Runs Hot Towing or Pulling Grades > Page 3804 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine Runs Hot Towing or Pulling Grades > Page 3805 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Fan Clutch: All Technical Service Bulletins Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3811 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3812 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3813 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3814 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3815 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3816 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 3817 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fan Clutch: > 05-06-04-008A > Apr > 05 > Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set Fuel Tank Vent: All Technical Service Bulletins Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set Bulletin No.: 05-06-04-008A Date: April 14, 2005 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P1172 or P2636, Fuel Gauge Reads Empty, Service Engine Soon (SES) Light On (Relocate Auxiliary Fuel Tank Vent Hose) Models: 2001-2005 Chevrolet Silverado (Cab Chassis Models Only) 2001-2005 GMC Sierra (Cab Chassis Models Only) with Auxiliary Fuel Tank Supercede: This bulletin is being revised to clarify the difference between the auxiliary fuel tank balance hose and vent hose. Please discard Corporate Bulletin Number 05-06-04-008 (Section 06 Engine/Propulsion System). Condition Some customers may comment that the SES light comes on and the fuel gauge reads empty. when This may occur when the vehicle is parked on an incline with the engine running. Diagnosis with a scan tool may reveal a DTC P1172 and/or P2636. Cause Important: A similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. The auxiliary fuel tank vent hose is located in the same "T" connection on the main tank vent hose as the auxiliary tank balance hose. During fuel transfer, the fuel is pumped out of the auxiliary tank to the main tank via the balance hose. The fuel is then sucked back into the auxiliary tank via the vent hose rather then dumping the fuel into the main tank. When the Powertrain Control Module (PCM) does not detect a fluid level transfer between the main tank and the auxiliary tank, the PCM shuts off the auxiliary tank pump and the fuel gauge goes to empty. Correction Follow the service procedure below to correct this condition. 1. Depending on the body upfitter, it may be necessary to raise the vehicle in order to gain access to the auxiliary tank balance hose. 2. Depending on the body upfitter, it may be necessary to remove the left rear tire/wheel assemblies in order to gain access to the auxiliary tank balance hose. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fan Clutch: > 05-06-04-008A > Apr > 05 > Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set > Page 3823 3. Locate the auxiliary fuel tank vent hose. The vent hose is the smaller diameter of the two hoses that comes from the auxiliary fuel tank and feeds into the main tank vent hose. 4. Disconnect the auxiliary tank vent hose from the main tank vent hose connection. 5. Install the cap supplied with kit, P/N 15213990, to the main tank vent hose connector where the auxiliary tank vent hose was just removed. 6. Locate the section of vent hose on the main tank between the fuel filler neck and the metal pipe. The smaller of the two hoses on the filler neck. 7. Cut the main tank vent hose between the filler neck and the metal pipe using an appropriate cutting tool. 8. Install the "T" and the two hose clamps supplied with kit, P/N 15213990, into the main tank vent hose. Tighten Tighten the hose clamps to 2.5 N.m (22 lb in). 9. Install the new auxiliary tank vent hose and clamp supplied with kit, P/N 15213990, to the "T" that was just installed. Tighten Tighten the hose clamp to 2.5 N.m (22 lb in). 10. Connect the new vent hose to the original auxiliary tank hose. 11. Secure the newly installed vent hose and the original auxiliary tank vent hose with plastic ties supplied in kit, P/N 15213990. 12. If necessary, reinstall the left rear tires/wheels assemblies. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fan Clutch: > 05-06-04-008A > Apr > 05 > Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set > Page 3824 13. If necessary, lower the vehicle. 14. Using a scan tool, clear the DTCs. 15. Start the vehicle and inspect for leaks. Important: Advise the customer that a similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fan Clutch: > 05-06-04-008A > Apr > 05 > Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set > Page 3830 3. Locate the auxiliary fuel tank vent hose. The vent hose is the smaller diameter of the two hoses that comes from the auxiliary fuel tank and feeds into the main tank vent hose. 4. Disconnect the auxiliary tank vent hose from the main tank vent hose connection. 5. Install the cap supplied with kit, P/N 15213990, to the main tank vent hose connector where the auxiliary tank vent hose was just removed. 6. Locate the section of vent hose on the main tank between the fuel filler neck and the metal pipe. The smaller of the two hoses on the filler neck. 7. Cut the main tank vent hose between the filler neck and the metal pipe using an appropriate cutting tool. 8. Install the "T" and the two hose clamps supplied with kit, P/N 15213990, into the main tank vent hose. Tighten Tighten the hose clamps to 2.5 N.m (22 lb in). 9. Install the new auxiliary tank vent hose and clamp supplied with kit, P/N 15213990, to the "T" that was just installed. Tighten Tighten the hose clamp to 2.5 N.m (22 lb in). 10. Connect the new vent hose to the original auxiliary tank hose. 11. Secure the newly installed vent hose and the original auxiliary tank vent hose with plastic ties supplied in kit, P/N 15213990. 12. If necessary, reinstall the left rear tires/wheels assemblies. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fan Clutch: > 05-06-04-008A > Apr > 05 > Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set > Page 3831 13. If necessary, lower the vehicle. 14. Using a scan tool, clear the DTCs. 15. Start the vehicle and inspect for leaks. Important: Advise the customer that a similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Page 3832 Fan Clutch: Service and Repair Fan Clutch Replacement ^ Tools Required J 46406 Fan Clutch Remover and Installer Removal Procedure 1. Remove the upper fan shroud. 2. Install the J 46406 to the fan clutch. 3. Remove the fan hub nut from the water pump in a counterclockwise rotation. 4. Remove the fan clutch bolts from the rear of the fan blade. 5. Separate the fan clutch from the fan blade. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Page 3833 1. Install the fan clutch bolts from the rear of the fan blade. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the fan clutch bolts. Tighten the bolts to 23 Nm (17 ft. lbs.). 3. Install the fan assembly. 4. Install the J 46406 to the fan clutch. Tighten the nut clockwise to 56 Nm (41 ft. lbs.). 5. Install the upper fan shroud. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Upper Front of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3838 Engine Coolant Temperature (ECT) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3839 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the coolant to a level below the engine coolant temperature (ECT) sensor. 2. Disconnect the ECT sensor electrical connector. 3. Remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3840 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor (1). Tighten Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector. 4. Fill the cooling system, if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Fan Shroud - Upper Fan Shroud: Service and Repair Fan Shroud - Upper W/RPO M74 Fan Shroud Replacement - Upper (W/M74) Removal Procedure 1. Loosen the air cleaner outlet duct clamps from the throttle body. 2. Loosen the air cleaner outlet duct clamps from the mass airflow sensor. 3. Remove the air cleaner outlet duct. 4. Remove the A/C line retainer from the fan shroud. 5. Remove the engine harness clip from the PCM cover. 6. Remove the TCM cover bolts. 7. Remove TCM cover from the fan shroud. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Fan Shroud - Upper > Page 3845 8. Loosen the TCM electrical connector bolts. 9. Disconnect the TCM electrical connectors (1). 10. Remove the TCM and cover. 11. Remove the fan shroud retainers. 12. Remove the fan shroud bolts 13. Remove the upper fan shroud. Installation Procedure 1. Install the upper fan shroud. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Fan Shroud - Upper > Page 3846 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the fan shroud bolts. Tighten the bolts to 9 Nm (80 inch lbs.). 3. Install the fan shroud retainers. 4. Connect the TCM electrical connectors (1). 5. Install the TCM and cover. 6. Tighten the TCM electrical connector bolts. Tighten the bolts to 8 Nm (71 inch lbs.). 7. Install the TCM cover to the fan shroud. 8. Install the TCM cover bolts. Tighten the bolts to 9 Nm (80 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Fan Shroud - Upper > Page 3847 9. Install the engine harness clip to the PCM cover. 10. Install the A/C line retainer to the fan shroud. 11. Install the air cleaner outlet duct. 12. Tighten the air cleaner outlet duct clamp at the throttle body. Tighten the clamp screws to 7 Nm (62 inch lbs.). 13. Tighten the air cleaner outlet duct clamp at the mass airflow sensor. Tighten the clamp screws to 7 Nm (62 inch lbs.). W/O RPO M74 Fan Shroud Replacement - Upper (W/O M74) Removal Procedure 1. Loosen the air cleaner outlet duct clamps from the throttle body. 2. Loosen the air cleaner outlet duct clamps from the mass airflow sensor. 3. Remove the air cleaner outlet duct. 4. If equipped remove the throttle body heater hose retainer from the fan shroud. 5. If equipped remove the inlet radiator hose retainer from the fan shroud. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Fan Shroud - Upper > Page 3848 6. Remove the fan shroud retainers. 7. Remove the fan shroud bolts 8. Remove the upper fan shroud. Installation Procedure 1. Install the upper fan shroud. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the fan shroud bolts. Tighten the bolts to 9 Nm (80 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Fan Shroud - Upper > Page 3849 3. Install the fan shroud retainers. 4. If equipped install the inlet radiator hose retainer to the fan shroud 5. If equipped install the throttle body heater hose retainer to the fan shroud. 6. Install the air cleaner outlet duct. 7. Tighten the air cleaner outlet duct clamp at the throttle body. Tighten the clamp screw to 7 Nm (62 inch lbs.). 8. Tighten the air cleaner outlet duct clamp at the mass airflow sensor. Tighten the clamp screw to 7 Nm (62 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Fan Shroud - Upper > Page 3850 Fan Shroud: Service and Repair Fan Shroud - Lower Fan Shroud Replacement - Lower Removal Procedure 1. Remove the cooling fan. 2. If equipped with engine oil cooler, remove the oil cooler hose clip from the lower fan shroud. 3. Lift the lower fan shroud up in order to disengage the fan shroud from the retaining clips on the radiator. Installation Procedure 1. Install the lower fan shroud to the retaining clips on the radiator and firmly push down. 2. If equipped with the engine oil cooler, Install the oil cooler hose clip to the lower fan shroud. 3. Install the cooling fan. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 3855 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 3856 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement Heater Core: Service and Repair Heater Core Replacement HEATER CORE REPLACEMENT (HEAT ONLY) REMOVAL PROCEDURE 1. Remove the heater/vent module. See: 2. Remove the heater core cover screws. 3. Remove the heater core cover. 4. Remove the heater core. INSTALLATION PROCEDURE 1. Install the heater core. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 3859 2. Install the heater core cover. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install heater core cover screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 4. Install the heater/vent module. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 3860 Heater Core: Service and Repair Heater Core Replacement - Delphi HEATER CORE REPLACEMENT (DELPHI) REMOVAL PROCEDURE 1. Remove the HVAC module assembly. See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/HVAC Module Assembly Replacement 2. Remove the screws from the heater core cover. 3. Remove the heater core cover (1) from the HVAC module assembly (2). 4. Remove the heater core cowl gasket (1) from the heater core (2). 5. Remove the heater core (2) from the HVAC module assembly (3). INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 3861 1. Install the heater core (2) to the HVAC module assembly (3). 2. Install the heater core cowl gasket (1) to the heater core (2). 3. Install the heater core cover (1) to the HVAC module assembly (2). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the heater core cover (1). Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the HVAC module assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 3862 Heater Core: Service and Repair Heater Core Replacement - Visteon HEATER CORE REPLACEMENT (VISTEON) REMOVAL PROCEDURE 1. Remove the HVAC module assembly. See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair 2. Remove the screws from the heater core cover. 3. Remove the heater core cover (1) from the HVAC module assembly (2). 4. Remove the heater core cowl gasket (1) from the heater core (2). 5. Remove the heater core (1) from the HVAC module assembly (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 3863 INSTALLATION PROCEDURE 1. Install the heater core (1) to the HVAC module assembly (2). 2. Install the heater core cowl gasket (1) to the HVAC module assembly (2). 3. Install the heater core cover (1) to the HVAC module assembly (2). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the heater core cover (1). Tighten Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 3864 Tighten the screws to 2 N.m (18 lb in). 5. Install the HVAC module assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet (With RPO Code HP2 Front) Heater Hose: Service and Repair Heater Hose Replacement - Inlet (With RPO Code HP2 Front) HEATER HOSE REPLACEMENT - INLET (W/ HP2 FRONT) REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Loosen the air cleaner outlet duct clamps at the following locations: - Throttle body - Mass airflow/intake air temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet duct. 4. Remove the air cleaner outlet duct. 5. Reposition the inlet heater hose clamp from the engine. 6. Remove the inlet heater hose from the engine. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet (With RPO Code HP2 Front) > Page 3869 7. Reposition the inlet heater hose clamp (4) from the auxiliary water pump (1). 8. Remove the inlet heater hose (6) from the auxiliary water pump (1). INSTALLATION PROCEDURE 1. Install the inlet heater hose (6) to the auxiliary water pump (1). 2. Position the inlet heater hose clamp (4) to the auxiliary water pump (1). 3. Install the inlet heater hose to the engine. 4. Position the inlet heater hose clamp to the engine. IMPORTANT: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet (With RPO Code HP2 Front) > Page 3870 5. Install the air cleaner outlet duct. 6. Install the radiator inlet hose clip to the outlet duct. NOTE: Refer to Fastener Notice in Service Precautions. 7. Tighten the air cleaner outlet duct clamps at the following locations: - Throttle body - MAF/IAT sensor Tighten Tighten the screws to 7 N.m (62 lb in). 8. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet (With RPO Code HP2 Front) > Page 3871 Heater Hose: Service and Repair Heater Hose Replacement - Inlet (With RPO Code HP2 Rear) HEATER HOSE REPLACEMENT - INLET (W/ HP2 REAR) TOOLS REQUIRED J 43181 Quick Connect Connector Removal Tool REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Using the J 43181 disconnect the heater hose from the heater core inlet. 2.1. Install the J 43181 to the heater core pipe. 2.2. Close the tool around the heater core pipe. 2.3. Firmly pull the tool into the quick connect end of the heater hose. 2.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 3. Reposition the inlet heater hose clamp (2) from the auxiliary water pump (1). 4. Remove the inlet heater hose (3) from the auxiliary water pump (1). INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet (With RPO Code HP2 Front) > Page 3872 1. Install the inlet heater hose (3) to the auxiliary water pump (1). 2. Position the inlet heater hose clamp (2) to the auxiliary water pump (1). 3. Connect the inlet heater hose to the heater core. 4. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 5. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair Radiator Drain Plug: Service and Repair Drain Cock Replacement Removal Procedure 1. Drain the cooling system. 2. Remove the radiator drain cock. Installation Procedure 1. Install the radiator drain cock. 2. Fill the cooling system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection Radiator Cap: Testing and Inspection Pressure Cap Testing ^ Tools Required J 24460-01 Cooling System Pressure Tester - J 42401 Radiator Cap / Surge Tank Test Adapter Pressure Cap Testing 1. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot. Remove the pressure cap. 2. Wash the pressure cap sealing surface with water. 3. Use the J 24460-01 (1) with J 42401 (2) in order to test the pressure cap. 4. Test the pressure cap for the following conditions: ^ Pressure release when the J 24460-01 exceeds the pressure rating of the pressure cap. ^ Maintain the rated pressure for at least 10 seconds.Note the rate of pressure loss. 5. Replace the pressure cap under the following conditions: ^ The pressure cap does not release pressure which exceeds the rated pressure of the cap. ^ The pressure cap does not hold the rated pressure. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Inlet Radiator Hose: Service and Repair Inlet Radiator Hose Replacement - Inlet (6.6L Engine) Removal Procedure 1. Drain the engine coolant. 2. Move the hose clamps back on the radiator inlet hose. 3. Remove the radiator inlet hose from the radiator. 4. Remove the radiator inlet hose from the water outlet tube. Installation Procedure 1. Install the radiator inlet hose to the water outlet tube. 2. Install the radiator inlet hose to the radiator. 3. Install the hose clamps on the radiator outlet hose. 4. Fill the engine coolant. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Inlet > Page 3884 Radiator Hose: Service and Repair Outlet Radiator Hose Replacement - Outlet (6.6L Engine) Removal Procedure 1. Drain the engine coolant. 2. Remove the upper and lower fan shroud. 3. Remove the surge tank outlet hose (2) from the surge tank. 4. Remove the radiator outlet hose from the water pump. 5. Remove the heater outlet hose from the radiator outlet hose. 6. Remove the radiator outlet hose from the radiator. 7. Remove the radiator outlet hose clip retainers from the brackets. 8. Remove the radiator outlet hose from the vehicle. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Inlet > Page 3885 1. Install the radiator outlet hose to the vehicle. 2. Install the radiator outlet hose and clamp to the radiator. Ensure the hose is positioned properly in order to prevent interference with the fan shroud. 3. Install the radiator outlet hose clip retainers to the brackets. 4. Install the surge tank outlet hose (2) to the surge tank. 5. Install the radiator outlet hose and clamp to the water pump. 6. Install the heater outlet hose to the radiator outlet hose. 7. Install the upper and lower fan shroud. 8. Fill the engine coolant. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Inlet > Page 3886 Radiator Hose: Service and Repair Radiator Vent Inlet Hose Replacement Radiator Vent Inlet Hose Replacement Removal Procedure 1. Drain the cooling system. 2. Reposition the vent inlet hose clamp from the radiator. 3. Remove the vent inlet hose from the radiator. 4. Reposition the vent inlet hose clamp from the surge tank. 5. Remove the vent inlet hose from the surge tank. Installation Procedure 1. Install the vent inlet hose to the surge tank. 2. Reposition the vent inlet hose clamp to the surge tank. 3. Install the vent inlet hose to the radiator. 4. Reposition the vent inlet hose clamp to the radiator. 5. Fill the cooling system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Inlet > Page 3887 Radiator Hose: Service and Repair Radiator Hose Quick Connect Fitting Radiator Hose Quick Connect Fitting Removal Procedure 1. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring. 2. Rotate the retaining ring (3) around the quick connector until the retaining ring is out of position and can be completely removed. 3. Remove the radiator outlet hose (2) from the quick connector fitting at the radiator (1). Installation Procedure 1. Important: Do not install the retaining ring (3) onto the fitting by pushing the retaining ring down over the fitting. Hook one of the open ends of the retaining ring (3) in one of the slots in the quick connector. 2. Rotate the retaining ring (3) around the connector until the retaining ring is positioned with all 3 ears through the 3 slots. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Inlet > Page 3888 3. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots. 4. Install the radiator outlet hose (2) onto the radiator quick connector fitting until a click is heard or felt.Pull back on the radiator outlet hose (2) to ensure a proper connection. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Locations Left Side Of The Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Locations > Page 3893 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Upper Front of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3898 Engine Coolant Temperature (ECT) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3899 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the coolant to a level below the engine coolant temperature (ECT) sensor. 2. Disconnect the ECT sensor electrical connector. 3. Remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3900 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor (1). Tighten Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector. 4. Fill the cooling system, if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair Thermostat: Service and Repair Thermostat Replacement (6.6L (LLY) Engine) Removal Procedure 1. Remove the water outlet. 2. Remove the bolt for the fuel line bracket. 3. Remove the fuel line bracket. 4. Remove the thermostat housing cover bolts. 5. Remove the thermostat housing cover. 6. Remove the thermostats and seals. Inspection Procedure 1. Inspect the thermostats for sticking, cracks, and/or leakage of wax. 2. Replace the thermostats if damage is found. 3. Clean the thermostat housing and thermostat housing cover sealing surfaces. Installation Procedure 1. Install the thermostats and seals to the thermostat housing.The rear thermostat (4) has 2 vent valves. Install with the vent valves towards the rear of engine. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Page 3904 2. Install the thermostat housing cover with a NEW gasket. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the thermostat housing cover bolts. Tighten the bolts to 21 Nm (15 ft. lbs.). 4. Install the fuel line bracket. 5. Install the fuel line bracket bolt. Tighten the bolt to 21 Nm (15 ft. lbs.). 6. Install the water outlet tube. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair Thermostat Housing: Service and Repair Thermostat Housing Crossover Replacement (6.6L (LLY) Engine) Removal Procedure 1. Remove the intake manifold cover. 2. Drain the cooling system. 3. Disconnect the negative battery cables. 4. Remove the upper fan shroud. 5. Remove the drive belt. Replacement in Engine Mechanical - 6.6L (LLY). 6. Disconnect the air conditioning (A/C) compressor clutch electrical connector (5). 7. Disconnect the A/C cut out switch electrical connector. 8. Remove the A/C compressor bolts. 9. Reposition the A/C compressor, with the hoses attached, to the right side of the engine compartment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair > Page 3908 10. Remove the generator positive cable to generator nut. 11. Remove the positive cable from the generator. 12. Remove the clip holding the positive cable to the engine front cover. 13. Remove the battery positive cable junction block to power steering pump bolt (1). 14. Move the generator positive cable and the junction block bracket aside. 15. Disconnect the generator electrical connector. 16. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair > Page 3909 17. Remove the power steering pump bracket bolts. 18. Reposition the power steering pump bracket and secure to the side. ^ Do not remove the power steering pump from the bracket. ^ The hoses and battery cables can remain on the power steering pump. 19. Remove the heater outlet hose bracket bolt from the generator bracket. 20. Remove the idler pulley. 21. Remove the generator bracket bolts. 22. Remove the generator bracket and position to the side. ^ The generator does not require removal. ^ The drive belt tensioner does not require removal. 23. Remove the oil fill tube. 24. Remove the water outlet. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair > Page 3910 25. Reposition the Exhaust Gas Recirculation (EGR) hose clamp at the EGR coolant pipe. 26. Remove the EGR coolant pipe bolt. 27. Remove the EGR coolant pipe with O-ring seal from the crossover. 28. Reposition the turbocharger coolant return pipe hose clamp. 29. Remove the turbocharger coolant return pipe hose. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair > Page 3911 30. Remove the fuel line bracket bolt at the thermostat housing crossover. 31. Remove the cooling fan pulley. 32. Remove the water pump inlet pipe bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair > Page 3912 33. Remove the thermostat housing bolts and nuts. 34. Remove the thermostat housing, with the bypass pipe. 35. Remove and discard the thermostat bypass pipe to water pump O-ring seal. 36. Remove and discard the thermostat housing gaskets. 37. If necessary, perform the following steps: 1. Remove the thermostat bypass pipe from the thermostat housing. 2. Remove and discard the thermostat bypass pipe O-ring seal. 3. Remove the thermostat cover bolts and cover. 4. Remove the thermostats. 5. Remove and discard the thermostat seals. 38. If required, clean and inspect the thermostat housing. Installation Procedure 1. If necessary, perform the following steps: 1. Install NEW seals to the thermostats. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair > Page 3913 2. Install the thermostats. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the thermostat cover and bolts. Tighten the bolts to 21 Nm (15 ft. lbs.). 4. Install a NEW O-ring seal to the thermostat bypass pipe. 5. Install the thermostat bypass pipe to the thermostat housing. 2. Install a NEW thermostat bypass pipe to water pump O-ring seal. 3. Install the thermostat housing using NEW gaskets. 4. Install the thermostat housing bolts and nuts Tighten the bolts/nuts to 21 Nm (15 ft. lbs.). 5. Install the water pump inlet pipe bolts. Tighten the bolts to 21 Nm (15 ft. lbs.). 6. Install the cooling fan pulley. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair > Page 3914 7. Install the fuel line bracket bolt at the thermostat housing crossover. Tighten the bolt to 21 Nm (15 ft. lbs.). 8. Install the turbocharger coolant return pipe hose. 9. Position the turbocharger coolant return pipe hose clamp. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair > Page 3915 10. Install the EGR coolant pipe with O-ring seal to the crossover. 11. Install the EGR coolant pipe bolt. Tighten the bolt to 25 Nm (18 ft. lbs.). 12. Position the EGR hose clamp at the EGR coolant pipe. 13. Install the water outlet. 14. Install the oil fill tube. 15. Position the generator bracket. 16. Install the generator bracket bolts. Tighten the bolt to 50 Nm (37 ft. lbs.). 17. Install the idler pulley. Tighten the bolt to 43 Nm (32 ft. lbs.). 18. Install the heater outlet hose bracket bolt to the generator bracket. Tighten the bolt to 21 Nm (15 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair > Page 3916 19. Position the power steering pump bracket. 20. Install the power steering pump bracket bolts. Tighten the bolt to 46 Nm (34 ft. lbs.). 21. Position the generator positive cable and the junction block bracket. 22. Install the battery positive cable junction block to power steering pump bolt (1). Tighten the bolt to 9 Nm (80 inch lbs.). 23. Install the clip holding the positive cable to the engine front cover. 24. Install the positive cable to the generator. 25. Install the generator positive cable to generator nut. Tighten the nut to 9 Nm (80 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair > Page 3917 26. Connect the ECT sensor electrical connector. 27. Connect the generator electrical connector. 28. Position the A/C compressor, with the hoses attached. 29. Install the A/C compressor bolts. Tighten the bolts to 50 Nm (37 ft. lbs.). 30. Connect the A/C cut out switch electrical connector. 31. Connect the A/C compressor clutch electrical connector (5). 32. Install the drive belt. Replacement in Engine Mechanical - 6.6L (LLY). 33. Install the upper fan shroud. 34. Connect the negative battery cables. 35. Fill the cooling system. 36. Install the intake manifold cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolt ................................................................................................................................. ...................................................... 25 Nm (18 ft. lbs.) Water Pump Inlet Pipe Bolts ........................... .......................................................................................................................................... 25 Nm (18 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3921 Water Pump: Service and Repair Water Pump Replacement (6.6L (LLY) Engine) Removal Procedure 1. Remove the left wheelhouse inner panel. 2. Remove the thermostat housing crossover. 3. Remove the crankshaft balancer. 4. Remove the water pump to engine coolant pipe nuts. 5. Remove the engine wiring harness retainer from the inner stud. 6. Remove the water pump bolts. Note the location of the bolts. The bolts are three different lengths. 7. Remove the water pump. 8. Remove and discard the water pump O-ring and coolant pipe gasket. 9. If required, clean and inspect the water pump. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3922 Installation Procedure 1. Lubricate the water pump O-ring with engine oil. 2. Install the engine coolant pipe gasket and water pump O-ring. 3. Install the water pump. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the water pump bolts. Ensure the correct length bolt is used in the proper location. Tighten the bolts to 21 Nm (15 ft. lbs.). 5. Install the engine wiring harness retainer on the water pump outlet pipe inner stud. 6. Install the water pump to engine coolant pipe nuts. Tighten the nuts to 21 Nm (15 ft. lbs.). 7. Install the thermostat housing crossover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3923 8. Install the crankshaft balancer. 9. Install the left wheelhouse inner panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-05-002 > Jul > 05 > Exhaust System Moan/Vibration at 55-60 MPH Catalytic Converter: Customer Interest Exhaust System - Moan/Vibration at 55-60 MPH Bulletin No.: 05-06-05-002 Date: July 27, 2005 TECHNICAL Subject: Exhaust Moan/Vibration (Replace Converter Assembly and Exhaust Muffler Assembly) Models: 2004-2005 Chevrolet Silverado 2500HD/3500HD Series Crew Cab Short Box Pickups 2004-2005 GMC Sierra 2500HD/3500HD Series Crew Cab Short Box Pickups with 6.6L Diesel Engine (VIN 2 - RPO LLY) Condition Some customers may comment on a moan or vibration at vehicle speeds approximately 87-97 km/h (55-60 mph) and at approximately 1700-1800 RPM. Correction Replace the catalytic converter assembly and exhaust muffler assembly using the procedure listed below. 1. Raise and suitably support the vehicle. 2. Remove the spare tire. 3. Install adjustable jack stands under the rear axle. 4. Remove the rear axle vent hose from the rear axle. 5. Remove the vent hose swivel clip from the rear brake crossover pipe. 6. Remove the rear shock absorbers lower bolts and nuts. 7. Lower the rear axle using the adjustable jack stands. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-05-002 > Jul > 05 > Exhaust System Moan/Vibration at 55-60 MPH > Page 3933 8. Loosen the catalytic converter coupling nuts. 9. With the aid of an assistant, support the exhaust muffler. 10. Gently pry up the catalytic converter coupling clip (1) (on the muffler end) in order to disengage the locator button (3) from the coupling clip. 11. With the aid of an assistant, slide the muffler rearward until the locator button is fully disengaged. 12. Remove the insulators from the frame hangers. 13. With the aid of an assistant, remove the muffler assembly from the vehicle. 14. Support the transmission with a suitable transmission jack. 15. Remove the transmission mount to transmission support nuts. 16. Raise the transmission off of the transmission support. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-05-002 > Jul > 05 > Exhaust System Moan/Vibration at 55-60 MPH > Page 3934 17. Remove the transmission support crossmember bolts. 18. Remove the transmission support crossmember. 19. Loosen the exhaust pipe clamp. 20. Slide the exhaust pipe clamp up onto the exhaust pipe. 21. Slide the catalytic converter hanger out of the insulator. 22. Remove the catalytic converter. 23. Apply water based lubricant to the exhaust pipe hanger bracket, in order to aid in installation. 24. Slide the catalytic converter hanger into the insulator. Important: Ensure that the manifold pipe is square to the exhaust pipe adapter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-05-002 > Jul > 05 > Exhaust System Moan/Vibration at 55-60 MPH > Page 3935 25. Slide the exhaust pipe clamp down and around the pipe connection. 26. Tighten the exhaust pipe clamp. Tighten Tighten the clamp to 40 N.m (30 lb ft). 27. Lower the transmission onto the transmission support. 28. Install the transmission mount to transmission support nuts. Tighten Tighten the bolts to 40 N.m (30 lb ft). 29. Remove the support from the transmission. 30. With the aid of an assistant, align the new muffler, locator button (3) to the catalytic converter coupling groove (2). 31. Install the muffler until the locator button is fully engaged by the coupling clip (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-05-002 > Jul > 05 > Exhaust System Moan/Vibration at 55-60 MPH > Page 3936 Important: Apply lubricant to the insulators to aid in installation. 32. Install the insulators to the frame hangers. 33. Tighten the catalytic converter coupling nuts until snug. 34. Once sung, tighten the catalytic converter coupling nuts. Tighten Tighten the nuts to 45 Nm (33 lb-ft.). 35. Raise the rear axle using the adjustable jack stands. 36. Install the rear shock absorbers lower bolts and nuts. Tighten Tighten the bolts to 95 N.m (70 lb ft). 37. Install the rear axle vent hose to the rear axle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-05-002 > Jul > 05 > Exhaust System Moan/Vibration at 55-60 MPH > Page 3937 38. Connect the vent hose swivel clip to the rear brake crossover pipe. 39. Remove the adjustable jack stands from under the rear axle. 40. Install the spare tire. 41. Lower the vehicle. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-05-002 > Jul > 05 > Exhaust System Moan/Vibration at 55-60 MPH Catalytic Converter: All Technical Service Bulletins Exhaust System - Moan/Vibration at 55-60 MPH Bulletin No.: 05-06-05-002 Date: July 27, 2005 TECHNICAL Subject: Exhaust Moan/Vibration (Replace Converter Assembly and Exhaust Muffler Assembly) Models: 2004-2005 Chevrolet Silverado 2500HD/3500HD Series Crew Cab Short Box Pickups 2004-2005 GMC Sierra 2500HD/3500HD Series Crew Cab Short Box Pickups with 6.6L Diesel Engine (VIN 2 - RPO LLY) Condition Some customers may comment on a moan or vibration at vehicle speeds approximately 87-97 km/h (55-60 mph) and at approximately 1700-1800 RPM. Correction Replace the catalytic converter assembly and exhaust muffler assembly using the procedure listed below. 1. Raise and suitably support the vehicle. 2. Remove the spare tire. 3. Install adjustable jack stands under the rear axle. 4. Remove the rear axle vent hose from the rear axle. 5. Remove the vent hose swivel clip from the rear brake crossover pipe. 6. Remove the rear shock absorbers lower bolts and nuts. 7. Lower the rear axle using the adjustable jack stands. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-05-002 > Jul > 05 > Exhaust System Moan/Vibration at 55-60 MPH > Page 3943 8. Loosen the catalytic converter coupling nuts. 9. With the aid of an assistant, support the exhaust muffler. 10. Gently pry up the catalytic converter coupling clip (1) (on the muffler end) in order to disengage the locator button (3) from the coupling clip. 11. With the aid of an assistant, slide the muffler rearward until the locator button is fully disengaged. 12. Remove the insulators from the frame hangers. 13. With the aid of an assistant, remove the muffler assembly from the vehicle. 14. Support the transmission with a suitable transmission jack. 15. Remove the transmission mount to transmission support nuts. 16. Raise the transmission off of the transmission support. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-05-002 > Jul > 05 > Exhaust System Moan/Vibration at 55-60 MPH > Page 3944 17. Remove the transmission support crossmember bolts. 18. Remove the transmission support crossmember. 19. Loosen the exhaust pipe clamp. 20. Slide the exhaust pipe clamp up onto the exhaust pipe. 21. Slide the catalytic converter hanger out of the insulator. 22. Remove the catalytic converter. 23. Apply water based lubricant to the exhaust pipe hanger bracket, in order to aid in installation. 24. Slide the catalytic converter hanger into the insulator. Important: Ensure that the manifold pipe is square to the exhaust pipe adapter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-05-002 > Jul > 05 > Exhaust System Moan/Vibration at 55-60 MPH > Page 3945 25. Slide the exhaust pipe clamp down and around the pipe connection. 26. Tighten the exhaust pipe clamp. Tighten Tighten the clamp to 40 N.m (30 lb ft). 27. Lower the transmission onto the transmission support. 28. Install the transmission mount to transmission support nuts. Tighten Tighten the bolts to 40 N.m (30 lb ft). 29. Remove the support from the transmission. 30. With the aid of an assistant, align the new muffler, locator button (3) to the catalytic converter coupling groove (2). 31. Install the muffler until the locator button is fully engaged by the coupling clip (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-05-002 > Jul > 05 > Exhaust System Moan/Vibration at 55-60 MPH > Page 3946 Important: Apply lubricant to the insulators to aid in installation. 32. Install the insulators to the frame hangers. 33. Tighten the catalytic converter coupling nuts until snug. 34. Once sung, tighten the catalytic converter coupling nuts. Tighten Tighten the nuts to 45 Nm (33 lb-ft.). 35. Raise the rear axle using the adjustable jack stands. 36. Install the rear shock absorbers lower bolts and nuts. Tighten Tighten the bolts to 95 N.m (70 lb ft). 37. Install the rear axle vent hose to the rear axle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-05-002 > Jul > 05 > Exhaust System Moan/Vibration at 55-60 MPH > Page 3947 38. Connect the vent hose swivel clip to the rear brake crossover pipe. 39. Remove the adjustable jack stands from under the rear axle. 40. Install the spare tire. 41. Lower the vehicle. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 06-08-50-009F > Dec > 10 > Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set Seat Occupant Sensor: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC B0092 Set Bulletin No.: 02-09-41-002A Date: March 24, 2004 TECHNICAL Subject: Air Bag Lamp On, Passenger Air Bag Indicator Always Reads OFF, DTC B0092 Set (Repair Passenger Presence System (PPS) Sensor Harness) Models: 2003-2004 Cadillac Escalade, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon XL with Sensor Indicator Inflatable Restraint Front Passenger/Child Presence Detector (RPO ALO) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 02-09-41-002 (Section 09 - Restraints). Condition Some customers may comment that the Air Bag Lamp is on and the Passenger Air Bag indicator always reads OFF. Upon investigation, the technician may find DTC B0092 set. Cause The cause of this condition may be a shorted Passenger Presence System (PPS) sensor wire. The PPS sensor harness is located under the front passenger seat. This harness may be pinched between the seat frame and the track/riser. Correction Locate the PPS sensor (1) and inspect the harness for proper routing. If the harness is pinched between the seat frame and the track/riser, use the procedure listed below to repair wire(s). 1. Move the front passenger seat to the full rearward and full tilt up position. 2. Loosen the seat frame to track/riser nut and remove the harness. 3. Tighten the seat frame to track/riser nut. 4. Repair any damaged wires. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set > Page 3957 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set > Page 3967 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3968 Catalytic Converter: Service and Repair Catalytic Converter Replacement (6.6L Engine) Removal Procedure 1. Raise and suitably support the vehicle. 2. Support the transmission with a suitable transmission jack. 3. Remove the transmission mount to transmission support nuts. 4. Raise the transmission off of the transmission support. 5. Remove the transmission support crossmember bolts. 6. Remove the transmission support crossmember. 7. If equipped with the 6.6L engine, remove the exhaust muffler nuts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3969 8. If equipped with a 6.6L engine, loosen the exhaust pipe clamp. 9. Slide the exhaust pipe clamp up onto the exhaust pipe adapter. 10. If equipped with a 6.6L engine, remove the catalytic converter. 11. Slide the catalytic converter hanger out of the exhaust pipe hanger bracket. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3970 1. If equipped with a 6.6L engine, install the catalytic converter. 2. Apply water based lubricant to the exhaust pipe hanger bracket, in order to aid in installation. 3. Slide the catalytic converter hanger into the exhaust pipe hanger bracket. 4. If equipped with the 6.6L engine, install the exhaust muffler nuts until snug. 5. Important: Ensure that the manifold pipe is square to the exhaust pipe adapter. If equipped with a 6.6L engine, slide the exhaust pipe clamp down and around the pipe connection. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the exhaust pipe clamp and muffler nuts. ^ Tighten the clamp to 40 Nm (30 ft. lbs.). ^ Tighten the nuts to 40 Nm (30 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3971 7. Lower the transmission onto the transmission support. 8. Install the transmission mount to transmission support nuts. Tighten the bolts to 40 Nm (30 ft. lbs.). 9. Remove the support from the transmission. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Left Right Exhaust Manifold Bolt/Nut ................................................................................................................... ..................................................... 38 Nm (28 ft. lbs.) Exhaust Manifold Heat Shield Bolts ...................................................................................................................................................... 10 Nm (89 inch lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Left Exhaust Manifold Replacement - Left (6.6L (LLY) Engine) Removal Procedure 1. Raise and suitably support the vehicle. 2. Remove the exhaust pipe heat shield bolts. 3. Reposition the heat shield to the side in order to access the exhaust pipe to exhaust manifold bolts. 4. Lower the vehicle in order to work through the front wheelhouse opening. 5. Remove the wheelhouse panel. 6. Remove the charged air cooler outlet duct. 7. Remove the exhaust pipe to exhaust manifold bolts (1, 2, and 3). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 3977 8. Remove the exhaust manifold heat shield bolts. 9. Remove the exhaust manifold heat shield. Right 10. Remove the exhaust manifold bolts and nuts in the proper sequence. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 3978 11. Remove the exhaust manifold. 12. Remove and discard the exhaust manifold gasket. 13. Clean and inspect the exhaust manifold. Installation Procedure 1. Install the exhaust manifold with gasket. 2. Install the exhaust manifold bolts/nuts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 3979 Right 3. Notice: Refer to Fastener Notice in Service Precautions. Use the sequence shown to properly tighten the exhaust manifold bolts. Tighten the bolts/nut to 38 Nm (28 ft. lbs.). 4. Install the exhaust manifold heat shield. 5. Install the exhaust manifold heat shield bolts. Tighten the bolts to 8 Nm (71 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 3980 6. Install the exhaust pipe gasket. Align the tab on the gasket to face outward. 7. Install the exhaust pipe and the bolts (1, 2, and 3) to the exhaust manifold. Tighten the bolts to 53 Nm (39 ft. lbs.). 8. Raise the vehicle. 9. Install the exhaust pipe heat shield bolts. Tighten the bolts to 8 Nm (71 inch lbs.). 10. Install the charged air cooler outlet duct. 11. Install the wheelhouse panel. 12. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 3981 Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Right Exhaust Manifold Replacement - Right (6.6L (LLY) Engine) Removal Procedure 1. Raise the vehicle enough in order to work through the wheelhouse opening. 2. Remove the wheelhouse panel. 3. Remove the exhaust manifold heat shield bolts. 4. Remove the exhaust manifold heat shield. 5. Remove the right exhaust pipe to the exhaust manifold bolts (3, 4, and 5). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 3982 Left 6. Remove the exhaust manifold bolts and nuts in the proper sequence. 7. Remove the exhaust manifold. 8. Remove the bolt for the oil level indicator tube bracket in order to remove the exhaust manifold gasket. 9. Remove and discard the exhaust manifold gasket. 10. Clean and inspect the exhaust manifold. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 3983 1. Install the exhaust manifold gasket to the cylinder head. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolt for the oil level indicator tube bracket. Tighten the bolt to 21 Nm (15 ft. lbs.). 3. Install the exhaust manifold. 4. Install the exhaust manifold bolts/nuts. Left 5. Using the sequence shown, properly tighten the exhaust manifold bolts. Tighten the bolt/nuts to 38 Nm (28 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 3984 6. Install the exhaust manifold heat shield. 7. Install the exhaust manifold heat shield bolts. Tighten the bolts to 8 Nm (71 inch lbs.). 8. Install the exhaust pipe gasket. Align the tab on the gasket to face outward. 9. Install the exhaust pipe bolts (3, 4, and 5). Tighten the bolts to 53 Nm (39 ft. lbs.). 10. Install the wheelhouse panel. 11. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement Exhaust Pipe: Service and Repair Exhaust Manifold Pipe Replacement Exhaust Manifold Pipe Replacement (6.0L, 6.6L, and 8.1L Engines) Removal Procedure 1. Raise and suitably support the vehicle. 2. Support the transmission with a suitable transmission jack. 3. Remove the transmission mount to transmission support nuts. 4. Raise the transmission off of the transmission support. 5. Remove the transmission support crossmember bolts. 6. Remove the transmission support crossmember. 7. If equipped with a 6.0L or 8.1L engine, remove the exhaust muffler. 8. If equipped with a 6.0L or 8.1L engine, perform the following: 1. Remove the clip around the engine harness and the oxygen sensor pigtail. 2. Disconnect the connector position assurance (CPA) retainer. 3. Disconnect the oxygen sensor electrical connector. 4. Remove the oxygen sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3989 9. If equipped with a 6.0L or 8.1L engine, remove the exhaust manifold pipe nuts. 10. Using the transmission jack, lower the transmission slightly. 11. If equipped with the 6.6L engine, remove the exhaust muffler nuts. 12. If equipped with a 6.6L engine, loosen the exhaust pipe clamp. 13. Slide the exhaust pipe clamp up onto the exhaust pipe adapter. 14. If equipped with a 6.0L or 8.1L engine, remove the exhaust manifold pipe. 15. Slide the exhaust manifold pipe hanger out of the exhaust pipe hanger bracket. 16. Discard the exhaust manifold pipe seal. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3990 17. If equipped with a 6.0L engine, with RPO Y91, remove the exhaust manifold pipe. 18. Slide the exhaust manifold pipe hanger out of the exhaust pipe hanger bracket. 19. Discard the exhaust manifold pipe seal. 20. If equipped with a 6.6L engine, remove the exhaust manifold pipe. 21. Slide the exhaust manifold pipe hanger out of the exhaust pipe hanger bracket. Installation Procedure 1. If equipped with a 6.6L engine, install the exhaust manifold pipe. 2. Apply water based lubricant to the exhaust pipe hanger bracket, in order to aid in installation. 3. Slide the exhaust manifold pipe hanger into the exhaust pipe hanger bracket. 4. If equipped with a 6.0L engine, with RPO Y91, install a new exhaust manifold pipe seal to the exhaust manifold pipe. 5. Install the exhaust manifold pipe. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3991 6. Apply lubricant to the exhaust pipe hanger bracket, in order to aid in installation. 7. Slide the exhaust manifold pipe hanger into the exhaust pipe hanger bracket. 8. If equipped with a 6.0L or 8.1L engine, install a new exhaust manifold pipe seal to the exhaust manifold pipe. 9. Install the exhaust manifold pipe. 10. Apply lubricant to the exhaust pipe hanger bracket, in order to aid in installation. 11. Slide the exhaust manifold pipe hanger into the exhaust pipe hanger bracket. 12. If equipped with the 6.6L engine, install the exhaust muffler nuts until snug. 13. Important: Ensure that the manifold pipe is square to the exhaust pipe adapter. If equipped with a 6.6L engine, slide the exhaust pipe clamp down and around the pipe connection. Notice: Refer to Fastener Notice in Service Precautions. 14. Tighten the exhaust pipe clamp and muffler nuts. ^ Tighten the clamp to 40 Nm (30 ft. lbs.). ^ Tighten the nuts to 40 Nm (30 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3992 15. If equipped with a 6.0L or 8.1L engine, install the exhaust manifold pipe nuts. Tighten the nuts to 50 Nm (39 ft. lbs.). 16. Using the transmission jack, raise the transmission. 17. If equipped with a 6.0L or 8.1L engine, and the exhaust manifold pipe was replaced perform the following: 1. Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensor. 2. Install the old oxygen sensor. Tighten the sensor to 42 Nm (31 ft. lbs.). 18. If equipped with a 6.0L or 8.1L engine, and the exhaust manifold pipe was not replaced perform the following: 0. Connect the oxygen sensor electrical connector. 1. Connect the CPA retainer. 2. Install the clip around the engine harness and the oxygen sensor pigtail. 19. If equipped with a 6.0L or 8.1L engine, remove the exhaust muffler. 20. Install the transmission support crossmember. 21. Install the transmission support crossmember bolts. Tighten the bolts to 95 Nm (70 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3993 22. Lower the transmission onto the transmission support. 23. Install the transmission mount to transmission support nuts. Tighten the bolts to 40 Nm (30 ft. lbs.). 24. Remove the support from the transmission. 25. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3994 Exhaust Pipe: Service and Repair Exhaust Pipe Replacement - Left Exhaust Pipe Replacement - Left (6.6L (LLY) Engine) Removal Procedure 1. Remove the right wheelhouse panel. 2. Remove the exhaust heat shield nuts (2) and heat shield (3) from the dash panel. 3. Remove the left exhaust pipe heat shield bolts. 4. Remove the heat shield. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3995 5. Remove the exhaust pipe bolts in the proper sequence. 6. Remove the exhaust pipe and gaskets. 7. Discard the gaskets. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3996 1. Position the exhaust pipe with a NEW gasket to the turbocharger. Align the tab on the gasket at the turbocharger to face inward. 2. Loosely install the bolts. 3. Position the exhaust pipe with a NEW gasket to the exhaust manifold. Align the tab on the gasket to face outward. 4. Loosely install the bolts. 5. Notice: Refer to Fastener Notice in Service Precautions. Tighten the exhaust pipe bolts in the sequence shown. Tighten the bolts to 53 Nm (39 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3997 6. Install the exhaust pipe heat shield bolts. Tighten the bolts to 8 Nm (71 inch lbs.). 7. Install the left side exhaust heat shield (3) at the dash panel. 8. Install the heat shield nuts (2). Tighten the nuts to 9 Nm (80 inch lbs.). 9. Install the right wheelhouse panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3998 Exhaust Pipe: Service and Repair Exhaust Pipe Replacement - Right Exhaust Pipe Replacement - Right (6.6L (LLY) Engine) Removal Procedure 1. Remove the turbocharger exhaust pipe. 2. Remove the exhaust pipe bolts in the proper sequence. 3. Remove the exhaust pipe, bracket and gaskets. 4. Discard the gaskets. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3999 1. Position the exhaust pipe with a NEW gasket to the turbocharger. Align the tab on the gasket at the turbocharger to face inward. 2. Loosely install the bolts. 3. Position the exhaust pipe with a NEW gasket to the exhaust manifold. Align the tab on the gasket to face outward. 4. Loosely install the bolts. 5. Notice: Refer to Fastener Notice in Service Precautions. Tighten the exhaust pipe bolts in the proper sequence. Tighten the bolts to 53 Nm (39 ft. lbs.). 6. Remove the turbocharger exhaust pipe. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Exhaust Hanger Mounting Bracket Replacement Exhaust Pipe/Muffler Hanger: Service and Repair Exhaust Hanger Mounting Bracket Replacement Exhaust Hanger Mounting Bracket Replacement (6.0L, 6.6L, and 8.1L Engines) Removal Procedure 1. Remove the exhaust manifold pipe. 2. Remove the catalytic converter. 3. If equipped with a 4L60-E automatic transmission, remove the exhaust pipe hanger bracket bolts. 4. If equipped with a 6.0L engine and a 4L80-E automatic transmission, remove the exhaust pipe hanger bracket bolts. 5. If equipped with a 6.0L, or 8.1L engine and a 4L80-E automatic transmission, remove the exhaust pipe hanger bracket bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Exhaust Hanger Mounting Bracket Replacement > Page 4004 6. If equipped with a 6.0L engine and a 5-speed manual transmission, remove the transmission bolts. 7. If equipped with a 6.0L engine and a 5-speed manual transmission, remove the exhaust pipe hanger bracket bolts. 8. If equipped with a 6.6L or 8.1L engine and a Allison transmission, remove the exhaust pipe hanger bracket bolts. 9. If equipped with a 6.6L or 8.1L engine and a 6-speed manual transmission, remove the exhaust pipe hanger bracket bolts. 10. Remove the exhaust manifold pipe bracket. Installation Procedure 1. Install the exhaust manifold pipe bracket. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Exhaust Hanger Mounting Bracket Replacement > Page 4005 2. If equipped with a 6.6L or 8.1L engine and a 6-speed manual transmission, install the exhaust pipe hanger bracket bolts. Tighten the bolts to 12 Nm (106 inch lbs.). 3. If equipped with a 6.6L or 8.1L engine and a Allison transmission, install the exhaust pipe hanger bracket bolts. Tighten the bolts to 12 Nm (106 inch lbs.). 4. If equipped with a 6.0L engine and a 5-speed manual transmission, install the exhaust pipe hanger bracket bolts. Tighten the bolts to 12 Nm (106 inch lbs.). 5. If equipped with a 6.0L engine and a 5-speed manual transmission, install the transmission bolts. Tighten the bolts to 100 Nm (74 ft. lbs.). 6. If equipped with a 6.0L or 8.1L engine and a 4L80-E automatic transmission, install the exhaust pipe hanger bracket bolts. Tighten the bolts to 12 Nm (106 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Exhaust Hanger Mounting Bracket Replacement > Page 4006 7. If equipped with a 6.0L engine and a 4L80-E automatic transmission, install the exhaust pipe hanger bracket bolts. Tighten the bolts to 12 Nm (106 inch lbs.). 8. If equipped with a 4L60-E automatic transmission, install the exhaust pipe hanger bracket bolts. Tighten the bolts to 17 Nm (13 ft. lbs.). 9. Install the catalytic converter. 10. Install the exhaust manifold pipe. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Exhaust Hanger Mounting Bracket Replacement > Page 4007 Exhaust Pipe/Muffler Hanger: Service and Repair Exhaust Hanger Replacement Exhaust Hanger Replacement (6.6L Engine with RPO YF2) Removal Procedure 1. Raise and suitably support the vehicle. 2. Remove the exhaust muffler hanger nuts. 3. Remove the hanger from the hanger insulator. Installation Procedure 1. Install the hanger into the hanger insulator. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the exhaust muffler hanger nuts. Tighten the nuts to 50 Nm (39 ft. lbs.). 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Floor Panel Heat Shield Replacement Heat Shield: Service and Repair Floor Panel Heat Shield Replacement Floor Panel Heat Shield Replacement Removal Procedure 1. Remove the exhaust manifold pipe, if necessary. 2. Remove the catalytic converter, if necessary. 3. Remove the exhaust front heat shield nuts. 4. Remove the exhaust front heat shield from the studs. 5. If vehicle is a regular cab pick-up truck, remove the exhaust heat shield nuts. 6. Remove the exhaust front heat shield (1) and/or the exhaust heat shield (2) from the studs. 7. If vehicle is a extended cab pick-up truck, remove the exhaust heat shield nuts. 8. Remove the exhaust heat shield (1, 2) from the studs. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Floor Panel Heat Shield Replacement > Page 4012 9. If vehicle is a crew cab pick-up truck, remove the exhaust heat shield nuts. 10. Remove the exhaust heat shields from the studs. Installation Procedure 1. If vehicle is a crew cab pick-up truck, install the exhaust heat shields to the studs. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the exhaust heat shield nuts. Tighten the exhaust heat shield nuts to 9 Nm (80 inch lbs.). 3. If vehicle is a extended cab pick-up truck, install the exhaust heat shield (1, 2) to the studs. 4. Install the exhaust heat shield nuts. Tighten the exhaust heat shield nuts to 9 Nm (80 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Floor Panel Heat Shield Replacement > Page 4013 5. If vehicle is a regular cab pick-up truck, install the exhaust front heat shield (1) and/or the exhaust heat shield (2) to the studs. 6. Install the exhaust heat shield nuts. Tighten the exhaust heat shield nuts to 9 Nm (80 inch lbs.). 7. Install the exhaust front heat shield to the studs. 8. Install the exhaust front heat shield nuts. Tighten the exhaust heat shield nuts to 9 Nm (80 inch lbs.). 9. Install the catalytic converter, if necessary. 10. Install the exhaust manifold pipe, if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Floor Panel Heat Shield Replacement > Page 4014 Heat Shield: Service and Repair Exhaust Heat Shield Replacement Exhaust Heat Shield Replacement Removal Procedure 1. Remove the exhaust muffler. 2. Remove the spare tire hoist. 3. If equipped with a 6 1/2 ft box, remove the exhaust heat shield bolts. 4. Remove the exhaust heat shield. 5. If equipped with a 8 ft box, remove the exhaust heat shield bolts. 6. Remove the exhaust heat shield. Installation Procedure 1. if equipped with a 8 ft box, install the exhaust heat shield. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the exhaust heat shield bolts. Tighten the exhaust heat shield bolts to 9 Nm (80 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Floor Panel Heat Shield Replacement > Page 4015 3. if equipped with a 6 1/2 ft box, install the exhaust heat shield. 4. Install the exhaust heat shield bolts. Tighten the exhaust heat shield bolts to 9 Nm (80 inch lbs.). 5. Install the spare tire hoist. 6. Install the exhaust muffler. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Floor Panel Heat Shield Replacement > Page 4016 Heat Shield: Service and Repair Exhaust Heat Shield Replacement - Dash Panel Exhaust Heat Shield Replacement - Dash Panel Removal Procedure 1. Raise and suitably support the vehicle. 2. Remove the exhaust heat shield nuts. 3. Remove the exhaust heat shield (1, 3) from the dash panel studs. 4. If removing the heat shield (3), remove the shield out thru the passenger side wheelwell. Installation Procedure 1. If installing the heat shield (3), install the shield thru the passenger side wheelwell. 2. Install the exhaust heat shield (1, 3) to the dash panel studs. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the exhaust heat shield nuts. Tighten the nuts to 9 Nm (80 inch lbs.). 4. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH Muffler: Customer Interest Exhaust System - Moan/Vibration at 55-60 MPH Bulletin No.: 05-06-05-002 Date: July 27, 2005 TECHNICAL Subject: Exhaust Moan/Vibration (Replace Converter Assembly and Exhaust Muffler Assembly) Models: 2004-2005 Chevrolet Silverado 2500HD/3500HD Series Crew Cab Short Box Pickups 2004-2005 GMC Sierra 2500HD/3500HD Series Crew Cab Short Box Pickups with 6.6L Diesel Engine (VIN 2 - RPO LLY) Condition Some customers may comment on a moan or vibration at vehicle speeds approximately 87-97 km/h (55-60 mph) and at approximately 1700-1800 RPM. Correction Replace the catalytic converter assembly and exhaust muffler assembly using the procedure listed below. 1. Raise and suitably support the vehicle. 2. Remove the spare tire. 3. Install adjustable jack stands under the rear axle. 4. Remove the rear axle vent hose from the rear axle. 5. Remove the vent hose swivel clip from the rear brake crossover pipe. 6. Remove the rear shock absorbers lower bolts and nuts. 7. Lower the rear axle using the adjustable jack stands. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 4025 8. Loosen the catalytic converter coupling nuts. 9. With the aid of an assistant, support the exhaust muffler. 10. Gently pry up the catalytic converter coupling clip (1) (on the muffler end) in order to disengage the locator button (3) from the coupling clip. 11. With the aid of an assistant, slide the muffler rearward until the locator button is fully disengaged. 12. Remove the insulators from the frame hangers. 13. With the aid of an assistant, remove the muffler assembly from the vehicle. 14. Support the transmission with a suitable transmission jack. 15. Remove the transmission mount to transmission support nuts. 16. Raise the transmission off of the transmission support. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 4026 17. Remove the transmission support crossmember bolts. 18. Remove the transmission support crossmember. 19. Loosen the exhaust pipe clamp. 20. Slide the exhaust pipe clamp up onto the exhaust pipe. 21. Slide the catalytic converter hanger out of the insulator. 22. Remove the catalytic converter. 23. Apply water based lubricant to the exhaust pipe hanger bracket, in order to aid in installation. 24. Slide the catalytic converter hanger into the insulator. Important: Ensure that the manifold pipe is square to the exhaust pipe adapter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 4027 25. Slide the exhaust pipe clamp down and around the pipe connection. 26. Tighten the exhaust pipe clamp. Tighten Tighten the clamp to 40 N.m (30 lb ft). 27. Lower the transmission onto the transmission support. 28. Install the transmission mount to transmission support nuts. Tighten Tighten the bolts to 40 N.m (30 lb ft). 29. Remove the support from the transmission. 30. With the aid of an assistant, align the new muffler, locator button (3) to the catalytic converter coupling groove (2). 31. Install the muffler until the locator button is fully engaged by the coupling clip (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 4028 Important: Apply lubricant to the insulators to aid in installation. 32. Install the insulators to the frame hangers. 33. Tighten the catalytic converter coupling nuts until snug. 34. Once sung, tighten the catalytic converter coupling nuts. Tighten Tighten the nuts to 45 Nm (33 lb-ft.). 35. Raise the rear axle using the adjustable jack stands. 36. Install the rear shock absorbers lower bolts and nuts. Tighten Tighten the bolts to 95 N.m (70 lb ft). 37. Install the rear axle vent hose to the rear axle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 4029 38. Connect the vent hose swivel clip to the rear brake crossover pipe. 39. Remove the adjustable jack stands from under the rear axle. 40. Install the spare tire. 41. Lower the vehicle. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH Muffler: All Technical Service Bulletins Exhaust System - Moan/Vibration at 55-60 MPH Bulletin No.: 05-06-05-002 Date: July 27, 2005 TECHNICAL Subject: Exhaust Moan/Vibration (Replace Converter Assembly and Exhaust Muffler Assembly) Models: 2004-2005 Chevrolet Silverado 2500HD/3500HD Series Crew Cab Short Box Pickups 2004-2005 GMC Sierra 2500HD/3500HD Series Crew Cab Short Box Pickups with 6.6L Diesel Engine (VIN 2 - RPO LLY) Condition Some customers may comment on a moan or vibration at vehicle speeds approximately 87-97 km/h (55-60 mph) and at approximately 1700-1800 RPM. Correction Replace the catalytic converter assembly and exhaust muffler assembly using the procedure listed below. 1. Raise and suitably support the vehicle. 2. Remove the spare tire. 3. Install adjustable jack stands under the rear axle. 4. Remove the rear axle vent hose from the rear axle. 5. Remove the vent hose swivel clip from the rear brake crossover pipe. 6. Remove the rear shock absorbers lower bolts and nuts. 7. Lower the rear axle using the adjustable jack stands. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 4035 8. Loosen the catalytic converter coupling nuts. 9. With the aid of an assistant, support the exhaust muffler. 10. Gently pry up the catalytic converter coupling clip (1) (on the muffler end) in order to disengage the locator button (3) from the coupling clip. 11. With the aid of an assistant, slide the muffler rearward until the locator button is fully disengaged. 12. Remove the insulators from the frame hangers. 13. With the aid of an assistant, remove the muffler assembly from the vehicle. 14. Support the transmission with a suitable transmission jack. 15. Remove the transmission mount to transmission support nuts. 16. Raise the transmission off of the transmission support. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 4036 17. Remove the transmission support crossmember bolts. 18. Remove the transmission support crossmember. 19. Loosen the exhaust pipe clamp. 20. Slide the exhaust pipe clamp up onto the exhaust pipe. 21. Slide the catalytic converter hanger out of the insulator. 22. Remove the catalytic converter. 23. Apply water based lubricant to the exhaust pipe hanger bracket, in order to aid in installation. 24. Slide the catalytic converter hanger into the insulator. Important: Ensure that the manifold pipe is square to the exhaust pipe adapter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 4037 25. Slide the exhaust pipe clamp down and around the pipe connection. 26. Tighten the exhaust pipe clamp. Tighten Tighten the clamp to 40 N.m (30 lb ft). 27. Lower the transmission onto the transmission support. 28. Install the transmission mount to transmission support nuts. Tighten Tighten the bolts to 40 N.m (30 lb ft). 29. Remove the support from the transmission. 30. With the aid of an assistant, align the new muffler, locator button (3) to the catalytic converter coupling groove (2). 31. Install the muffler until the locator button is fully engaged by the coupling clip (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 4038 Important: Apply lubricant to the insulators to aid in installation. 32. Install the insulators to the frame hangers. 33. Tighten the catalytic converter coupling nuts until snug. 34. Once sung, tighten the catalytic converter coupling nuts. Tighten Tighten the nuts to 45 Nm (33 lb-ft.). 35. Raise the rear axle using the adjustable jack stands. 36. Install the rear shock absorbers lower bolts and nuts. Tighten Tighten the bolts to 95 N.m (70 lb ft). 37. Install the rear axle vent hose to the rear axle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 4039 38. Connect the vent hose swivel clip to the rear brake crossover pipe. 39. Remove the adjustable jack stands from under the rear axle. 40. Install the spare tire. 41. Lower the vehicle. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Muffler: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation Power Seat Control Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Muffler: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 4045 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Muffler: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 4051 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Page 4052 Muffler: Service and Repair Muffler Replacement (6.0L, 6.6L, and 8.1L Engines) Removal Procedure 1. Raise and suitably support the vehicle. 2. Remove the spare tire, if necessary. 3. Install adjustable jack stands under the rear axle, if necessary. 4. If equipped with a 8.6 or 9.5 inch ring gear, remove the rear axle vent hose from the rear axle, if necessary. 5. Remove the vent hose swivel clip from the rear brake crossover pipe, if necessary. 6. If equipped with a 10.5 inch ring gear, remove the rear axle vent hose from the rear axle, if necessary. 7. Remove the vent hose swivel clip from the rear brake crossover pipe, if necessary. 8. Remove the rear shock absorbers lower bolts and nuts, if necessary. 9. Lower the rear axle using the adjustable jack stands, if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Page 4053 10. If equipped with a 6.0L or 8.1L engine, perform the following: 1. Unclip the oxygen sensor connector from the frame. 2. Disconnect the Connector Position Assurance (CPA) retainer. 3. Disconnect the oxygen sensor electrical connector. 11. If equipped with a 6.0L or 8.1L engine, perform the following: 1. Unclip the oxygen sensor connector from the support. 2. Disconnect the CPA retainer. 3. Disconnect the oxygen sensor electrical connector. 12. If equipped with a 6.0L or 8.1L engine, perform the following: 1. Unclip the oxygen sensor connector from the support. 2. Disconnect the CPA retainer. 3. Disconnect the oxygen sensor electrical connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Page 4054 13. If equipped with a 6.0L engine, perform the following: ^ Unclip the oxygen sensor connector from the frame. ^ Disconnect the CPA retainer. ^ Disconnect the oxygen sensor electrical connector. 14. If equipped with a 6.0L or 8.1L engine, remove the exhaust muffler nuts. 15. Loosen the exhaust pipe clamp. 16. With the aid of an assistant, support the exhaust muffler. 17. If equipped with a 6.6L engine, remove the exhaust muffler nuts. 18. With the aid of an assistant, support the exhaust muffler. 19. If equipped with a 6.0L or 8.1L engine, remove the insulators from the frame hangers. 20. With the aid of an assistant, slide the muffler rearward in order to remove the muffler from the catalytic converter. 21. Remove the insulators from the muffler hangers. 22. Remove the exhaust manifold pipe gasket, if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Page 4055 23. If equipped with a 6.6L engine, remove the insulators from the frame hangers. 24. With the aid of an assistant, slide the muffler rearward in order to remove the muffler from the exhaust muffler pipe. 25. Remove the exhaust muffler gasket, if necessary. 26. Remove the insulators from the muffler hangers. 27. If equipped with a 6.0L or 8.1L engine, remove the oxygen sensor if the muffler is being replaced. 28. If the muffler is NOT being replaced as an assembly, the band clamp MUST be replaced. Perform the following: 0. Mark the position of the band clamp on the intermediate exhaust pipe. 1. Remove the band clamp from the exhaust pipe by grinding the weld. 2. Install a NEW band clamp onto the exhaust pipe. Installation Procedure 1. If equipped with a 6.0L or 8.1L engine, and the muffler was replaced re-install the old oxygen sensor. 2. Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensor. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the oxygen sensor. Tighten the sensor to 42 Nm (31 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Page 4056 4. Important: Apply lubricant to the insulators to aid in installation. If equipped with a 6.6L engine, install the insulators to the muffler hangers. 5. Install a new exhaust muffler gasket. 6. With the aid of an assistant, slide the muffler forward in order to install the muffler to the exhaust muffler pipe. 7. Install the insulators to the frame hangers. 8. Important: Apply lubricant to the insulators to aid in installation. If equipped with a 6.0L or 8.1L engine, install the insulators to the muffler hangers. 9. Install a new exhaust manifold pipe gasket. 10. With the aid of an assistant, slide the muffler forward in order to install the muffler to the catalytic converter. 11. Install the insulators to the frame hangers. 12. If equipped with a 6.6L engine, install the exhaust muffler nuts. Tighten the nuts to 40 Nm (30 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Page 4057 13. If equipped with a 6.0L or 8.1L engine, position the NEW band clamp on the intermediate exhaust pipe, using the alignment mark created previously. The band clamp bolt must NOT be positioned below the exhaust pipe. 14. Install the exhaust muffler nuts. 15. Tighten the exhaust pipe clamp bolt. ^ Tighten the nuts to 40 Nm (30 ft. lbs.). ^ Tighten the clamp to 44 Nm (33 ft. lbs.). 16. If equipped with a 6.0L engine, perform the following: 1. Connect the oxygen sensor electrical connector. 2. Connect the CPA retainer. 3. Clip the oxygen sensor connector to the frame. 17. If equipped with a 6.0 L or 8.1 L engine, perform the following: 0. Connect the oxygen sensor electrical connector. 1. Connect the CPA retainer. 2. Clip the oxygen sensor connector to the support. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Page 4058 18. If equipped with a 6.0L or 8.1L engine, perform the following: 0. Connect the oxygen sensor electrical connector. 1. Connect the CPA retainer. 2. Clip the oxygen sensor connector to the support. 19. If equipped with a 6.0L or 8.1L engine, perform the following: 0. Connect the oxygen sensor electrical connector. 1. Connect the CPA retainer. 2. Clip the oxygen sensor connector to the frame. 20. Raise the rear axle using the adjustable jack stands, if necessary. 21. Install the rear shock absorbers lower bolts and nuts, if necessary. Tighten the bolts to 95 Nm (70 ft. lbs.). 22. If equipped with a 10.5 inch ring gear, install the rear axle vent hose to the rear axle, if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Page 4059 23. Connect the vent hose swivel clip to the rear brake crossover pipe, if necessary. 24. If equipped with a 8.6 or 9.5 inch ring gear, install the rear axle vent hose to the rear axle, if necessary. 25. Connect the vent hose swivel clip to the rear brake crossover pipe, if necessary. 26. Remove the adjustable jack stands from under the rear axle, if necessary. 27. Install the spare tire, if necessary. 28. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair Exhaust Pipe Gasket: Service and Repair Exhaust Seal Replacement Removal Procedure 1. Raise and suitably support the vehicle. 2. If equipped with a 4.3L, 4.8L, or 5.3L engine, perform the following: 1. Remove the clip from around the engine harness and the oxygen sensor pigtail. 2. Disconnect the connector position assurance (CPA) retainer. 3. Disconnect the forward oxygen sensor electrical connector. 3. If equipped with a 4.3L, 4.8L, or 5.3L engine, perform the following: 1. Unclip the oxygen sensor electrical connector from the hose clip. 2. Disconnect the CPA retainer. 3. Disconnect the oxygen sensor electrical connector (1). 4. If equipped with a 6.0L or 8.1L engine, perform the following: 1. Disconnect the CPA retainer. 2. Disconnect the oxygen sensor electrical connector (1). 5. Support the catalytic converter or exhaust manifold pipe with adjustable jackstands. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair > Page 4064 6. If equipped with a 4.3L, 4.8L, or 5.3L engine, remove the left exhaust manifold pipe nuts. 7. If equipped with a 4.3L, 4.8L, or 5.3L engine, remove the right exhaust manifold pipe nuts. 8. If equipped with a 6.0L or 8.1L engine, remove the right exhaust manifold pipe nuts. 9. If equipped with a 6.0L or 8.1L engine, perform the following: 1. Remove the left exhaust manifold pipe nuts. 2. Remove the exhaust hanger mounting bracket bolts. 10. Lower the catalytic converter or exhaust manifold pipe using the adjustable jackstands. 11. Remove the exhaust manifold pipe seal(s). Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair > Page 4065 1. Install the exhaust manifold pipe seal(s). 2. Raise the catalytic converter or exhaust manifold pipe using the adjustable jackstands. 3. Notice: Refer to Fastener Notice in Service Precautions. If equipped with a 6.0L or 8.1L engine, perform the following: 1. Install the exhaust hanger mounting bracket bolts. 2. Install the left exhaust manifold pipe nuts. ^ Tighten the bolts to 12 Nm (106 inch lbs.). ^ Tighten the nuts to 50 Nm (39 ft. lbs.). 4. If equipped with a 6.0L or 8.1L engine, install the right exhaust manifold pipe nuts. Tighten the nuts to 50 Nm (39 ft. lbs.). 5. If equipped with a 4.3L, 4.8L, or 5.3L engine, install the right exhaust manifold pipe nuts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair > Page 4066 6. If equipped with a 4.3L, 4.8L, or 5.3L engine, install the left exhaust manifold pipe nuts. Tighten the nuts to 50 Nm (39 ft. lbs.). 7. If equipped with a 6.0L or 8.1L engine, perform the following: 1. Connect the oxygen sensor electrical connector (1). 2. Connect the CPA retainer. 8. Remove the adjustable jackstands from catalytic converter or exhaust manifold pipe. 9. If equipped with a 4.3L, 4.8L, or 5.3L engine, perform the following: 1. Connect the oxygen sensor electrical connector (1). 2. Connect the CPA retainer. 3. Clip the oxygen sensor electrical connector to the hose clip. 10. If equipped with a 4.3L, 4.8L, or 5.3L engine, perform the following: 1. Connect the forward oxygen sensor electrical connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair > Page 4067 2. Connect the CPA retainer. 3. Install the clip around the engine harness and the oxygen sensor pigtail. 11. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-02-118-002 > Feb > 05 > Steering - 'Service Rear Wheel Steering' Message Body Control Module: Customer Interest Steering - 'Service Rear Wheel Steering' Message Bulletin No.: 05-02-118-002 Date: February 03, 2005 TECHNICAL Subject: DTC C0455, "Service Rear Wheel Steering", System Jumps from 4-Wheel Steer to 2-Wheel Steer (Reprogram BCM) Models: 2003-2005 Chevrolet Silverado, Suburban 2003-2005 GMC Sierra, Yukon XL with 4-Wheel Steer (RPO NYS) Condition Some customers may comment that the system will jump from 4-wheel steer to 2-wheel steer and the DIC displays the message "Service Rear Wheel Steering". Diagnosis will show DTC C0455-Front Steering Position Sensor malfunction. Cause This condition may be caused by a Class2 communication issue. Correction Reprogram the BCM. 2005 Model Year Vehicles: New software calibration, P/N 15248410, was released on TIS version 12 - broadcast to dealers on December 4, 2004. 2003-2004 Model Year Vehicles: New software calibration, P/N 15259330 ('03 Model Year) and P/N 15259331 ('04 04 Model Year), was released on TIS version 1.75 - broadcast to dealers on January 24, 2005. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-02-118-002 > Feb > 05 > Steering - 'Service Rear Wheel Steering' Message Body Control Module: All Technical Service Bulletins Steering - 'Service Rear Wheel Steering' Message Bulletin No.: 05-02-118-002 Date: February 03, 2005 TECHNICAL Subject: DTC C0455, "Service Rear Wheel Steering", System Jumps from 4-Wheel Steer to 2-Wheel Steer (Reprogram BCM) Models: 2003-2005 Chevrolet Silverado, Suburban 2003-2005 GMC Sierra, Yukon XL with 4-Wheel Steer (RPO NYS) Condition Some customers may comment that the system will jump from 4-wheel steer to 2-wheel steer and the DIC displays the message "Service Rear Wheel Steering". Diagnosis will show DTC C0455-Front Steering Position Sensor malfunction. Cause This condition may be caused by a Class2 communication issue. Correction Reprogram the BCM. 2005 Model Year Vehicles: New software calibration, P/N 15248410, was released on TIS version 12 - broadcast to dealers on December 4, 2004. 2003-2004 Model Year Vehicles: New software calibration, P/N 15259330 ('03 Model Year) and P/N 15259331 ('04 04 Model Year), was released on TIS version 1.75 - broadcast to dealers on January 24, 2005. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel Steering Shaft: All Technical Service Bulletins Steering - Underhood Clunk Heard/Felt in Steering Wheel TECHNICAL Bulletin No.: 00-02-35-003N Date: March 26 2008 Subject: Clunking Noise Under Hood and Can Be Felt in Steering Wheel and/or Steering Column (Replace Upper Intermediate Steering Shaft [I-Shaft] Assembly) Models: 2002-2006 Cadillac Escalade Models 1999-2007 Chevrolet Silverado Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Models (Classic) 2000-2006 GMC Yukon, Yukon XL Models 2003-2006 HUMMER H2 Attention: This Service Bulletin DOES NOT include Mid-Size Utilities such as Buick Rainier, Chevrolet TrailBlazer Models, GMC Envoy Models or Oldsmobile Bravada. Refer to Service Bulletin 02-02-35-006A or newer for Mid-Size Utilities. Supercede: This bulletin is being revised to add diagnostic information (refer to Diagnostic Tips) to check the lower steering column bearing as a potential source of the noise. Please discard Corporate Bulletin Number 00-02-35-003M (Section 02-Steering). Condition Some customers may comment on a clunk-type noise coming from under the hood that also can be felt in the steering wheel. These conditions may be more noticeable when turning at low speeds on rough road surfaces. Diagnostic Tips Use the information below to help diagnose the source of the noise. ^ The lower steering column bearing may create the same noise as the intermediate shaft. Before replacing the I-shaft, verify the noise isn't being caused by movement from the lower steering column bearing. Check the bearing for movement by pushing up and down on the I-shaft where it attaches to the steering column. ^ Frame Snap and/or Popping Type Noise - A frame snap or popping type noise can be duplicated on rough or smooth road surfaces with steering wheel input to the left or the right. This type of noise can be HEARD and is typically louder with the windows rolled down. For additional information refer to Corporate Bulletin Number 03-08-61-002F or newer - Snap/Popping Type Noise Coming from Front of Vehicle (Remove Front Crossmember Change Fastener Orientation). ^ Intermediate Shaft Clunk - Intermediate shaft clunk is heard and FELT in the steering wheel and/or steering column area typically while driving on rough road surfaces with steering wheel input. Correction Important: ^ I-shaft P/N 19153614 has been designed to replace previous designed dampened and non-dampened I-shafts. The physical difference in the yoke size will accommodate all vehicles listed in this bulletin. ^ Due to the design of the new I-shaft, it is not possible to lubricate/grease the I-shaft. Replace the steering column upper intermediate shaft with an improved design shaft that will eliminate the clunk noise using the procedure listed below. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 4089 1. Set the front wheels in the straight ahead position. Notice: On the 2002 and later model year vehicles the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil. 2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles. 3. For 2002 and later vehicles install the J 42640 in the steering column lower access hole. 4. From under the hood remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft. 5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft. 6. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the carpet away from the accelerator pedal position (APP) sensor. 2. Remove the two nuts retaining the accelerator pedal to the bulkhead. 3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 4090 7. From inside the vehicle remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection. 8. Remove the upper intermediate steering shaft assembly. 1. From inside the vehicle slide the shaft down and off the steering column. 2. From inside the vehicle slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle. 9. Replace the upper intermediate shaft. 10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft. 11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft. 12. Install the upper bolt and nut. Tighten Tighten the bolt to 47 N.m (35 lb ft). 13. Install the lower bolt and nut. Tighten Tighten the bolt to 50 N.m (37 lb ft). 14. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the accelerator pedals into position on the bulkhead. 2. Install the two retaining nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Reposition the carpet into place. Parts Information Warranty Information For vehicles repaired under warranty use, the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 4091 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 4097 1. Set the front wheels in the straight ahead position. Notice: On the 2002 and later model year vehicles the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil. 2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles. 3. For 2002 and later vehicles install the J 42640 in the steering column lower access hole. 4. From under the hood remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft. 5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft. 6. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the carpet away from the accelerator pedal position (APP) sensor. 2. Remove the two nuts retaining the accelerator pedal to the bulkhead. 3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 4098 7. From inside the vehicle remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection. 8. Remove the upper intermediate steering shaft assembly. 1. From inside the vehicle slide the shaft down and off the steering column. 2. From inside the vehicle slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle. 9. Replace the upper intermediate shaft. 10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft. 11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft. 12. Install the upper bolt and nut. Tighten Tighten the bolt to 47 N.m (35 lb ft). 13. Install the lower bolt and nut. Tighten Tighten the bolt to 50 N.m (37 lb ft). 14. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the accelerator pedals into position on the bulkhead. 2. Install the two retaining nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Reposition the carpet into place. Parts Information Warranty Information For vehicles repaired under warranty use, the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 4099 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4100 Body Control Module: Locations Body Control Module (BCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4101 Body Control Module (BCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4104 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4105 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4106 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4107 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4108 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4109 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4110 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4111 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4112 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4113 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4114 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4115 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4116 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4117 Body Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4118 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4119 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4120 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4121 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4122 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4123 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4124 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4125 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4126 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4127 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4128 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4129 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4130 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4131 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4132 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4133 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4134 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4135 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4136 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4137 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4138 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4139 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4140 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4141 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4142 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4143 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4144 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4145 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4146 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4147 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4148 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4149 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4150 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4151 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4152 Body Control Module: Connector Views Body Control Module (BCM) - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4153 Body Control Module (BCM) - C2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4154 Body Control Module (BCM) - C2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4155 Body Control Module (BCM) - C2 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4156 Body Control Module (BCM) - C3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4157 Body Control Module (BCM) - C3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4158 Body Control Module (BCM) - C4 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4159 Body Control Module (BCM) - C4 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4160 Body Control Module (BCM) - C5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4161 Body Control Module (BCM) - C6 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4162 Body Control Module (BCM) - C6 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4163 Body Control Module: Electrical Diagrams Door Control Module Diagram 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4164 Door Control Module Diagram 2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4165 Door Control Module Diagram 2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4166 Door Control Module Diagram 3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4167 Door Control Module Diagram 3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 4168 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The body control module (BCM) monitors several inputs in order to arm and disarm the CTD system. The BCM controls the alarm function outputs. When the BCM detects an unauthorized entry (any door opened), the BCM applies ground to the horn, the park lamp and the headlamp relays. The BCM will send messages to the security telltale in the instrument cluster through the Class 2 serial data link. The BCM has the following 8 basic modes for operating the CTD system. The more detailed descriptions are below. - Off state - Idle state - Disarmed state - Ready-to-arm state - Arm initiated state - Arm delay state - Armed state - Alarm state The BCM has the following 6 discrete inputs in order to monitor the CTD system: - Ignition 1 - Driver door latch (door jamb) switch - Passenger door latch (door jamb) switch - Door lock relay - Door key switch - Passenger door unlock relay The BCM applies ground once per second for approximately 2 minutes, or until a valid input to disarm the system is received by the BCM. The Body Control Module (BCM) contains the theft deterrent system logic. The BCM reads the Passlock(TM) data from the Passlock(TM) sensor. If the Passlock(TM) data is correct, the BCM will pass theft. The BCM will then transmit the fuel continue password to the VCM/PCM. During the tamper mode the vehicle may start. The vehicle will then stall. If the BCM receives the wrong Passlock(TM) data, the VTD will immediately go into the tamper mode. The tamper mode will lock-out the vehicle fuel injectors for 10 minutes. The SECURITY indicator will flash while the VTD is in the tamper mode. If the Passlock(TM) sensor sends a correct password to the BCM when the ignition is in the ON position, the BCM will send a fuel enable signal to the VCM/PCM. The VCM/PCM will not disable the fuel due to any BCM message for the remainder of the ignition cycle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION The procedures below are designed to set-up the body control module (BCM) correctly during BCM related service. Before you start, read these procedures carefully and completely. IMPORTANT: The following procedures must be followed: 1. Programming the BCM. 2. Programming Theft Deterrent System Components, if equipped with Passlock System. PROGRAMMING THE BCM IMPORTANT: After the procedure is completed, the personalization settings of the BCM are set to a default setting. Inform the customer that the personalization must be set again. Perform the BCM special function Request BCM Info. for service programming system (SPS), then follow the SPS instructions. Refer to Service Programming System (SPS) in Programming. PROGRAMMING THEFT DETERRENT SYSTEM COMPONENTS IMPORTANT: This procedure has to be performed only for vehicles equipped with Passlock System. Perform the Programming Theft Deterrent System Components in Theft Deterrent after successfully finishing the Setup New BCM procedure. If the Programming Theft Deterrent System Components in the Theft Deterrent procedure is not performed after a BCM replacement, one of the following conditions will occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank or start. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON, with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 4171 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable(s). 2. Remove the knee bolster. 3. Disconnect the brown connector. 4. Disconnect all other connectors (1). 5. Remove the BCM from the sliding bracket. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 4172 1. Slide the BCM onto the bracket. 2. Connect all the connectors (1) except the brown connector. 3. Connect the brown connector. 4. Install the knee bolster. 5. Connect the negative battery cable(s). 6. Reprogram the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. 7. Perform the Passlock Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 4177 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 4178 Engine Control Module: Technical Service Bulletins Diesel Engine - Damage Due To Power-Up Devices INFORMATION Bulletin No.: 06-06-01-007F Date: March 31, 2010 Subject: Information On Identifying Duramax(TM) Diesel LB7, LLY, LMM, LBZ Overpower Engine Breakdown or Non-Function Due to Aftermarket Power-Up Devices vs. Non Overpower Engine Non-Function of Pistons, Cylinders, Valvetrain Components and/or Turbocharger DTC P003A Set Models: 2001-2010 Chevrolet Silverado 2003-2009 Chevrolet Kodiak 2006-2010 Chevrolet Express 2001-2010 GMC Sierra 2003-2009 GMC TopKick 2006-2010 GMC Savana Equipped With Duramax(TM) Turbocharged Diesel Engine RPOs LB7, LLY, LMM, LBZ Please Refer to GMVIS Supercede: This bulletin is being revised to add text to the end of the Caution statement. Please discard Corporate Bulletin Number 06-06-01-007E (Section 06 - Engine/Propulsion System). Caution Customers should be informed if a hard part failure is observed in the engine, transmission, transfer case and/or other driveline components, it is likely that powertrain components were weakened to the point of premature failure, while subjected to the higher stresses from Aftermarket Power-Up Devices. Failures associated with the installation of Aftermarket Power-Up Devices, which have been verified, are not covered under the terms of the New Vehicle Warranty. In the majority of these cases, the Fixed Operations Manager (FOM) (in Canada, Warranty Manager) should be contacted and the remaining portion of the powertrain portion of the New Vehicle Warranty blocked. GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage. General Motors Position On Aftermarket Power-Up Devices Important General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. Refer to Service Bulletin Number 04-06-04-054A or newer - Warranty Admin. - Non-GM Parts and Accessories (Aftermarket). Important For further information on aftermarket power-up kits, refer to February 2006 Emerging Issues Course Number 10206.02D. In Canada, information on aftermarket power-up kits was covered in the April 2006 TAC TALK program. Aftermarket power-up devices are non-approved by General Motors. These devices are usually piggy-backed in the main engine harness or remain connected to the diagnostic connector to upload the calibration to the ECM. Recent warranty reviews of returned engines show engine breakdown or non-function due to power-up devices that are utilized for increased horsepower and torque. The following information will assist technicians in identifying overpower engine breakdown or non-function due to aftermarket power-up devices vs. non overpower engine breakdown or non-function. Non-GM parts can alter the design of the vehicle. GM dealers need to be aware of the quality of parts being installed on vehicles. If failure occurs as a result of installation of sub-par parts, warranty coverage may be denied. Refer to Service Bulletin Number 04-06-04-054A or newer Warranty Admin. - Non-GM Parts and Accessories (Aftermarket). Installed Power-Up Kit Aftermarket power-up kits have become a very popular add on for performance-minded customers. These devices can add horsepower and torque and can add additional stress to the engine. These aftermarket calibrations take the Duramax(TM) powertrain outside of its design torque and horsepower rating. They do this by altering air/fuel ratios and injector timing, resulting in excessive cylinder pressure and temperature. When these calibrated parameters are altered, it will upset the design balance and can lead to a reduction of engine life expectancy. Generally, in inspection of Duramax(TM) engine failure due to power-up failures, two or more cylinders will be affected. Installed Power-Up Kit - Once installed, the calibration may mask itself with the factory original calibration ID and may remain the same. Refer to Service Bulletin Number 08-06-04-006F or newer - Information on Identifying Non-GM Calibration Usage for LMM Duramax(TM) Diesel Engine. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 4179 - A Tech 2(R) will not positively enable you to identify the use of a power-up device. - Some companies that offer power-up devices claim increases of 150 or more horsepower and 300 or more lb/ft pounds of torque. - A vehicle that is used to the power-up device potential 100% of the time will see earlier engine wear and breakdown. - A vehicle that takes advantage of additional power, but on a less frequent basis, may not see premature engine wear and breakdown until later in the engine's life. - A vehicle not pushed to its limits of the power-up device often may not encounter premature wear and breakdown until after the engine is out of warranty. Duramax(TM) Powertrain Horsepower / Torque Ratings The following horsepower and torque increase over the past years required new internal components to accommodate the increase. - LB7 - 300 hp with 520 ft/lb of torque for model years 2000-2004 - LLY - 310 hp with 605 ft/lb of torque for model years 2004-2008 - LBZ - 360 hp with 650 ft/lb of torque for model year 2006-2008 - LMM - 365 hp with 660 ft/lb of torque for model year 2007-2009 LBZ Improvements To reliably achieve an increase in 50 horsepower with 45 ft/lb torque, the Duramax (TM) diesel had to be revised in many areas. A few of the revisions on the 2006 LBZ were: - New pistons with a revised compression ratio. - Wrist pins that are larger in diameter. - Connecting rods with added material to increase the I section strength. - Engine block and machining changes - Cylinder heads Duramax(TM) Life Expectancy The Duramax(TM) 6.6L V8 Turbo Diesel Engine is sold with a warranty of 100,000 miles/160,000 kilometers. The Duramax(TM) has been tested to survive upwards of 200,000 miles/320,000 kilometers. The Duramax(TM) powertrain is designed for reliability, peak horsepower and torque within its design limits. When a customer installs a power-up device, it drastically reduces the mileage ratings. Important Cylinder Wall Spotting (commonly referred to leopard spots) is from the induction hardening process of the top 1/3 of the cylinder wall. This is normal for the Duramax (TM) Diesel. Identifying Fuel Related Aftermarket Power-Up Devices Aftermarket companies have developed a performance pressure relief fuel valve for Duramax(TM) diesel engines. Refer to above graphic illustration. The performance pressure relief fuel valve attaches to the fuel rail in place of the OEM valve and will not allow any fuel return to the tank, giving 100% of the fuel to be available for additional engine performance. This may cause additional fuel related driveability concerns and may set the following DTCs: - DTC P1093 Fuel Rail Pressure (FRP) Low During Power Enrichment - DTC P0087 Fuel Rail Pressure (FRP) Too Low Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 4180 Aftermarket companies have developed a replacement performance/economy fuel injector nozzle. Refer to above illustration. The performance/economy fuel injector nozzles replace the OEM fuel injector nozzles. The aftermarket companies claim increased horsepower, improved fuel atomization, lower exhaust gas temperatures and increase fuel economy. This may cause additional fuel related driveability concerns and may cause internal engine damage to the pistons and fuel injector nozzles. Identifying Overpower Engine Premature Wear and Breakdown When premature wear and breakdown is encountered due to an aftermarket power-up device, it has some very specific characteristics to the internal engine components. The following list will assist in identifying these characteristics as you tear down the engine. - Pistons will be cracked in the lip area, or a hole in the pistons. - Pistons can also be melted on the lip of the combustion bowl, or the top of the pistons can be melted. - Crosshatch will be polished off the cylinder wall in the major thrust face of cylinder below ring belt travel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 4181 - Piston pin bore will show signs of scoring, the wrist pins will be discolored, and can have oil coking on them. The connecting rod bushing surface will have accelerated wear. The above illustration shows a connecting rod bushing. - Oil coking on the underside of the piston between the wrist pin bosses. - Signs of bearing fretting will also be noticed on the connecting rod and main bearing caps. Refer to the above illustration for fretting of main bearing cap 1 and back side of connection rod bearing 2. - Excessive heat in engine compartment caused by overpower device. Refer to above illustration (1). Non Overpower Engine Premature Wear and Breakdown The following pictures show results of overheat, overspeed, low/no oil pressure or injector breakdown and how they differ from aftermarket power-up device premature wear and breakdown. Engine Overheat Overheat can be caused by a loss of coolant or a general cooling system failure. Some of the indicators of overheat are: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 4182 - Melted pistons. - Head gasket breakdown or non-function. - Warped cylinder heads. - Crankshaft and connecting rod discolored. Engine Overspeed Causes If an engine has been run faster than design capability (redline), and has caused damage as a result, it may be a result of one of the following conditions: - Leaking or failed turbocharger (TC) oil seals. - Oil evident in the intake runners and compressor side of the TC. - Starting fluid use or alternative fuel added to the engine such as ether. Engine Overspeed Results The following are indicators that an overspeed event took place: - Valve train damage. - Pushrods that are bent (4). - Broken valve bridge buttons after cylinder head removal (2). - Rocker arm tip damage (1). - Dry or rusted cylinders from the use of ether, propane or nitrous oxide. - Piston to valve contact. - Cam gear pin shear. Lack of Oil Pressure Lack of lubrication causes rapid bearing wear or bearing to seize. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 4183 Bearing failure. Spun main bearings. Engine Premature Wear and Breakdown Due to Improper Function of Fuel Injector A fuel injector may fracture a piston or melt a piston but the damage will be limited to that cylinder only and all other pistons and cylinder walls are OK. In some cases hydraulic lock will occur on the suspected cylinder with an over-fueling fuel injector. Hydraulic lock on the suspected cylinder will cause a bent connecting rod. This can be verified with piston protrusion measurements. 2007-2010 RPO LMM Only Turbocharger DTC P003A Set General Motors has identified a turbocharger (TC) failure mode involving Power-Up Kits that causes soot leakage and DTC P003A to be set. The Power-Up Kits create an overtemperature condition from the increased exhaust gas temperatures that results in a permanent and excessive turbine housing distortion at the TC case halves. 1. A technician may observe one or more of the following conditions: - DTC P003A being set as Current or in History. - An unusual odor emanating from the TC due to an overtemperature condition. - Soot leaking and accumulating at the V-band clamp that secures the TC case halves together. - Limited or unresponsive travel when Commanding the TC Vane Pos. Ctrl. Solenoid ON and OFF with a scan tool. 2. If DTC P003A is found as Current or in History, OR there is evidence of soot leakage (1) in the area of the V-band clamp (1), then technicians MUST verify if the engine control module (ECM) has a Power-Up Kit aftermarket calibration installed or an aftermarket hardware device has been installed. Refer to Service Bulletin Number 08-06-04-006F or newer for the calibration verification information and procedures. How to Handle a Suspect Engine Failure Due to a Power-Up Device Dealers should not automatically decline warranty assistance on engine failures due to the fact that a power-up device or modification is evident or suspected. The technician must identify that the failure is due to a power-up device by teardown analysis and diagnosis of the engine components. The following steps should be taken if an engine failure occurs and it is suspected that the modification or addition of a power-up device maybe the cause of the engine failure. If unclear of this process or direction feel free to contact your Fixed Operations Manager (in Canada, Warranty Manager) for further support. 1. The technician should use proper engine diagnostics to lead him/her to the failed engine components. The Aftermarket Power-Up Kit Check List should be followed and if it is determined that at least three of the Aftermarket Power-Up Kit Check List items match the engine component failures then it can be decided that the failure is not a warrantable claim. 2. Engine failures that meet at least three criteria of the Aftermarket Power-Up Kit Check List are considered failures that are not manufacturer's defects in workmanship or materials. 3. The dealership should contact the PQC, open a case to review the findings and make the final decision on warranty coverage. The Fixed Operations Manager (in Canada, Warranty Manager) should be notified of the PQC decision. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 4184 4. Denied claims should be documented as follows: 1. The Aftermarket Power-Up Kit Check List completed with the technicians detailed written findings of the diagnosis on the repair order and retained in the repair order file. 2. Photographs of the failed parts should be retained in the repair order file. 5. The customer should be advised that the failure of their engine was not due to a manufacturer's defect in workmanship or materials and therefore the warranty claim is denied on this failure. Aftermarket Power-Up Kit Check List Important Print and use this aftermarket power-up kit check list when performing an engine disassembly investigation of overpower engine breakdown or non-function. Retain a copy of this checklist and photographs of the failed parts in the repair order file. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4185 LF Of The Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 Engine Control Module: Diagrams Engine Control Module (ECM) - C1 Engine Control Module (ECM) - C1 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4188 Engine Control Module (ECM) - C1 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4189 Engine Control Module (ECM) - C1 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4190 Engine Control Module (ECM) - C1 Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4191 Engine Control Module: Diagrams Engine Control Module (ECM) - C2 Engine Control Module (ECM) - C2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4192 Engine Control Module (ECM) - C2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4193 Engine Control Module (ECM) - C2 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4194 Engine Control Module (ECM) - C2 Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4195 Engine Control Module (ECM) - C2 Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4196 Engine Control Module: Diagrams Engine Control Module (ECM) - C3 Engine Control Module (ECM) - C3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4197 Engine Control Module (ECM) - C3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4198 Engine Control Module (ECM) - C3 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4199 Engine Control Module (ECM) - C3 Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Passlock Function Engine Control Module: Description and Operation Passlock Function VEHICLE/POWERTRAIN CONTROL MODULE The VCM/PCM communicates with the BCM over the Class 2 serial data line. When the BCM determines a no start condition, it sends a Class 2 serial data password to the VCM/PCM in order to disable the fuel injection system. If the BCM receives the expected voltage from the Passlock(TM) sensor, the BCM sends a class 2 serial data password to the VCM/PCM in order to enable the fuel injection system. The VCM/PCM then allows the vehicle to start correctly. If the Class 2 serial data password from the BCM to the VCM/PCM is not within the Vehicle Security Status Message, the fuel injectors will shut OFF during a start attempt. The SECURITY telltale will be illuminated for 10 minutes. If the VCM/PCM does not receive the same password from the BCM as the last learned one, the vehicle will start and then stalls due to the Fuel Lockout. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Passlock Function > Page 4202 Engine Control Module: Description and Operation Engine Control Module (ECM) ENGINE CONTROL MODULE (ECM) DESCRIPTION The engine control module (ECM) processes the various input information. The ECM sends the necessary electrical responses to control fuel delivery. The input information has an interrelation to more than one output. One failed input can affect more than one systems operation. Diagnostic System Check - Computers and Control Systems The Diagnostic System Check Computers and Control Systems is an organized approach to identify a problem caused by an electronic engine control system malfunction. This diagnostic check must be the starting point for any driveability complaint diagnosis. The diagnostic directs the technician to the next logical step in diagnosing the complaint. Use the Engine Scan Tool Data Definitions list for a comparison after fulfilling the following items: Complete the Diagnostic System Check-Computers and Control Systems. - Confirm that the on-board diagnostics are functioning properly. - Confirm there are no diagnostic trouble codes. The Engine Scan Tool Definitions are an average of display values recorded from normal operating vehicles. The definitions intend to represent what a normal functioning system should display. IMPORTANT: Do not use a scan tool that displays faulty data. Report the problem to the manufacturer. Using a malfunctioning scan tool can result in misdiagnosis and unnecessary parts replacement. Use only the parameters listed in the Engine Scan Tool Data Definitions for diagnosis. When a scan tool reads other parameters, General Motors recommends not using the values for use in diagnosis. For more description on the values and the use of the scan tool to diagnose the ECM inputs, refer to the applicable diagnostic file. When all the values are within the range illustrated in the Engine Scan Tool Data Definitions, refer to Symptoms - Computers and Control Systems. Control Module Communications The control module system has a computer, the engine control module (ECM), to control fuel delivery, timing, and some emission control systems. The control module system monitors a number of engine and vehicle functions and controls the following operations through the fuel injection control module (FICM): Fuel rail pressure - Fuel injector - Fuel injector pulse width The diesel ECM, located in the engine compartment, is the control center of the control module system. The engine control module used on the electronic fuel injected 6.6L diesel is referred to as a ECM. The ECM constantly looks at the information from various sensors, and controls the systems that affect vehicle performance. The ECM performs the diagnostic function of the system. The ECM can recognize operational problems, alert the driver through the MIL. Service Engine Soon, and store one or more diagnostic trouble codes (DTCs) which identify the problem areas to aid the technician in making repairs. See the specific diagnosis procedure for more information. Malfunction Indicator Lamp (MIL) Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Passlock Function > Page 4203 The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Aftermarket (Add-On) Electrical And Vacuum Equipment Any equipment installed on a vehicle after leaving the factory that connects to the electrical or vacuum systems of the vehicle defines aftermarket (Add-On) electrical and vacuum equipment. The vehicle design makes no allowances for this type of equipment. NOTE: - Do not attach add-on vacuum operated equipment to this vehicle. The use of add-on vacuum equipment may result in damage to vehicle components or systems. - Connect any add-on electrically operated equipment to the vehicle's electrical system at the battery (power and ground) in order to prevent damage to the vehicle. The add-on electrical equipment, even when installed to these strict guidelines, may still cause the powertrain system to malfunction. This may also include any equipment which is not connected to the electrical system of the vehicle such as portable telephones and radios. Therefore, the first step in diagnosing any powertrain problem is to eliminate all of the aftermarket electrical equipment from the vehicle. After this is done, if the problem still exists, diagnose the problem in the normal manner. Computers and Control Systems Information The driveability and emissions information describes the function and operation of the control module. The emphasis is placed on the diagnosis and repair of problems related to the system. Engine Components, Wiring Diagrams, and Diagnostic Trouble Code (DTC) tables: The Component Locations - The Wiring Diagrams - The Control Module Terminal End View and Terminal Definitions - The Diagnostic System Check - Computers and Control Systems - The Diagnostic Trouble Code (DTC) tables The Component System includes the following items: The component and circuit description - The On-vehicle service for each subsystem - The Functional checks with the diagnostic tables - How To Use Electrical Systems Diagnostic Information The DTCs also contain the diagnostic support information containing the circuit or the system information, and helpful diagnostic information. Wiring Harness Service The control module harness electrically connects the control module to the various solenoids, switches, and sensors in the vehicle engine compartment and passenger compartment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Passlock Function > Page 4204 Replace the wire harnesses with the proper part number replacement. When splicing signal wires into a harness, use the wiring that has high temperature insulation. Consider the low amperage and voltage levels utilized in the powertrain control systems. Make the best possible bond at all splices. Use rosin-core solder in these areas. Molded-on connectors require complete replacement of the connector. Splice a new connector into the harness. Replacement connectors and terminals are listed in Group 8.965 in the Standard Parts Catalog. Connectors and Terminals In order to prevent shorting between opposite terminals, use care when probing a connector and when replacing terminals. Damage to the components could result. Always use jumper wires between connectors for circuit checking. Never probe through the Weather-Pack seals. The J 35616-B Connector Test Adapter Kit , or the equivalent, contains an assortment of flexible connectors used in order to probe the terminals during the diagnosis. The fuse remover and the BT-8616 Test Tool, or the equivalent, is used for removing a fuse and to adapt the fuse holder to a meter for diagnosis. Open circuits are often difficult to locate by sight because oxidation or terminal misalignment are hidden by the connectors. Merely wiggling a connector on a sensor or in the wiring harness may temporarily correct the open circuit. Oxidized or loose connections may cause intermittent problems. Be certain the type of connector and terminal before making any connector or terminal repair. Weather-Pack and Com-Pack III terminals look similar, but are serviced differently. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Passlock Function > Page 4205 Engine Control Module: Description and Operation Turbocharger ENGINE CONTROL MODULE (ECM) The ECM controls all turbocharger control functions. The ECM monitors information from various sensor inputs that include the following: - The accelerator pedal position (APP) sensor - The engine coolant temperature (ECT) sensor - The mass airflow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The boost pressure sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 4206 Engine Control Module: Service and Repair ENGINE CONTROL MODULE (ECM) REPLACEMENT Service of the engine control module (ECM) should consist of either replacement of the ECM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the ECM to be replaced, the replacement ECM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty ECM and install the new service ECM. REMOVAL PROCEDURE IMPORTANT: - To prevent internal ECM damage, the ignition switch must be OFF when disconnecting or connecting power to the ECM. - Remove any debris from the ECM connector surfaces before servicing the ECM. Inspect the ECM module connector gaskets when diagnosing or replacing the ECM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the ECM. - The replacement ECM must programmed. - It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100%. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5000km (3,000 mi) from the last engine oil change. 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 2. Disconnect the negative battery cable. 3. Disconnect the ECM electrical connectors (2). 4. Release the ECM cover retaining tabs. 5. Remove the ECM cover from the bracket. 6. Remove the ECM cover. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 4207 1. Install the ECM. IMPORTANT: The cover must be fully installed prior to the electrical connections being made to ensure the ECM is fully seated in the bracket. 2. Install the ECM cover to the bracket. 3. Engage the ECM cover retaining tabs. 4. Connect the ECM electrical connectors (2). 5. Connect the negative battery cable. 6. If a NEW ECM was installed, program the ECM. Refer to Service Programming System (SPS) in Programming. See: Testing and Inspection/Programming and Relearning 7. Perform the turbocharger learn procedure. Refer to Turbocharger Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations FUEL PUMP RELAY - SECONDARY (Vehicles with Dual Tanks Only) Fuel Pump Relay-Secondary-With Dual Tanks The Fuel Pump Relay - Secondary is attached to the Underhood Fuse Block Bracket. The Underhood Fuse Block is located at the left side of the engine compartment, to the rear of the battery. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection Fuel Temperature Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4221 Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4222 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SYSTEM DESCRIPTION The accelerator pedal position (APP) system along with the vehicle electronics and components is used to calculate and control the amount of acceleration and deceleration via fuel injector control. This eliminates the need for a mechanical cable attachment from the accelerator pedal to a throttle body. The APP system includes, but is not limited to, the following components : - The accelerator pedal position (APP) sensor assembly - The engine control module (ECM) Accelerator Pedal Position (APP) Sensor The accelerator pedal position (APP) sensor is mounted on the accelerator pedal control assembly. The sensor is made up of 3 individual sensors within one housing. Three separate signal, low reference, and 5-volt reference circuits are used in order to interface the accelerator pedal sensor assembly with the ECM. Each sensor has a unique functionality to determine pedal position. The ECM uses the APP sensor to determine the amount of acceleration or deceleration desired by the person driving the vehicle. The APP sensor 1 voltage should increase as the accelerator pedal is depressed, from below 1.0 volt at 0 pedal travel to above 2 volts at 100 percent pedal travel. APP sensor 2 voltage should decrease from above 4 volts at 0 pedal travel to below 3.0 volts at 100 percent pedal travel. APP sensor 3 voltage should decrease from above 3.8 volts at 0 percent pedal travel to below 3.3 volts at 100 percent pedal travel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4223 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION (APP) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector. 3. Reposition the carpet to access the lower nut. 4. Remove the accelerator pedal nuts. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4224 1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Service Precautions. 2. Install the accelerator pedal nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Connect the APP sensor electrical connector. 4. Reposition the carpet. 5. Install the CPA retainer. 6. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 7. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle and a wide open throttle (WOT). 8. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 9. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Mass Air Flow (MAF) Sensor: Locations Right Side Of The Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4228 Right Side Of Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4229 Intake Air Temperature (IAT)/Mass Airflow (MAF) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4230 Mass Air Flow (MAF) Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector (1). 2. Remove the MAF/IAT sensor TORX(R) screws. 3. Remove the MAF/IAT sensor (1). INSTALLATION PROCEDURE 1. Install the MAF/IAT sensor (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4231 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the MAF/IAT sensor TORX(R) screws. Tighten Tighten the screws to 8 N.m (70 lb in). 3. Connect the MAF/IAT sensor electrical connector (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations Barometric Pressure Sensor: Locations Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 4235 Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 4236 BARO Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 4237 Barometric Pressure Sensor: Service and Repair BAROMETRIC PRESSURE (BARO) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the barometric pressure (BARO) sensor electrical connector. 2. Push the BARO sensor (1) downward in order to remove it from the bracket. INSTALLATION PROCEDURE 1. Push the BARO sensor (1) upward in order to remove it from the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 4238 2. Connect the BARO sensor electrical connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Brake Pressure Switch > Component Information > Locations Chassis And License Lamp Harnesses Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Right Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4245 Camshaft Position (CMP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Replacement CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the cooling fan pulley. 2. Remove the camshaft position (CMP) sensor bolt. 3. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Lubricate the CMP sensor O-ring with clean engine oil. 2. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the CMP sensor bolt. Tighten Tighten the bolt to 10 N.m (89 lb in). 4. Install the cooling fan pulley. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement > Page 4248 Camshaft Position Sensor: Service and Repair Camshaft Reluctor Replacement Camshaft Reluctor Replacement Removal Procedure Notice: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 1. Remove the engine front cover. 2. While holding the secondary oil pump shaft with a hex driver, remove the oil pump driven gear nut. 3. Remove the oil pump driven gear. 4. Important: DO NOT remove the reluctor from the oil pump drive gear. The reluctor is timed to the gear and once removed the correct timing will be lost. Remove the oil pump drive gear and crankshaft sensor reluctor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement > Page 4249 5. Remove the camshaft reluctor screws. 6. Remove the camshaft reluctor. 7. Clean and Inspect the camshaft reluctor for damage. Replace the reluctor if damage is found. Installation Procedure 1. Position the camshaft reluctor to the camshaft gear. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the camshaft reluctor bolts. Tighten the bolts to 9 Nm (80 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement > Page 4250 3. Important: Do not damage the teeth on the reluctor. Install the oil pump drive gear and reluctor to the crankshaft. 4. Install the oil pump driven gear. 5. While holding the secondary oil pump shaft with a hex driver, install the oil pump driven gear nut. Tighten the nut to 100 Nm (74 ft. lbs.). 6. Install the engine front cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations SEO Harness Routing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Upper Front of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4257 Engine Coolant Temperature (ECT) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4258 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the coolant to a level below the engine coolant temperature (ECT) sensor. 2. Disconnect the ECT sensor electrical connector. 3. Remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4259 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor (1). Tighten Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector. 4. Fill the cooling system, if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Starter Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4263 Right Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4264 Crankshaft Position (CKP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4265 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the right wheelhouse panel. 3. Disconnect the crankshaft position (CKP) sensor electrical connector. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. 6. If necessary, remove the CKP sensor spacer bolts. 7. If necessary, remove the CKP sensor spacer. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4266 1. If necessary, lubricate a NEW CKP spacer O-ring with clean engine oil. 2. If necessary, install the NEW O-ring to the CKP sensor spacer. IMPORTANT: The crankshaft position sensor spacers are machined with different timing positions. However, if the crankshaft position sensor spacer requires replacement, replace with a grade "C" spacer. 3. If necessary, install the CKP sensor spacer. NOTE: Refer to Fastener Notice in Service Precautions. 4. If necessary, install the CKP sensor spacer bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). 5. Lubricate a NEW CKP sensor O-ring with clean engine oil. 6. Install the NEW O-ring to the CKP sensor. 7. Install the CKP sensor. 8. Install the CKP sensor bolt. Tighten Tighten the bolt to 10 N.m (89 lb in). 9. Connect the CKP sensor electrical connector. 10. Install the right wheelhouse panel. 11. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Fuel Tank - Primary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 4270 Fuel Tank - Secondary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 4271 Fuel Level Sensor: Diagrams Fuel Level Sensor - Primary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 4272 Fuel Level Sensor - Secondary W/Dual Tanks Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 4273 Fuel Level Sensor - Primary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 4274 Fuel Level Sensor - Secondary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 4275 Fuel Level Sensor: Description and Operation FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The engine control module (ECM) sends the fuel level information via the class 2 circuit to the instrument panel cluster (IPC). This information is used for the instrument panel (I/P) fuel gage and the low fuel warning indicator, if applicable. The ECM also monitors the fuel level input for various diagnostics. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 4276 Fuel Level Sensor: Service and Repair FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel level sensor electrical connector (1). 3. Remove the sensor retaining clip (3). 4. Squeeze the locking tangs (2) and remove the fuel level sensor. INSTALLATION PROCEDURE 1. Install the fuel level sensor. 2. Install the sensor retaining clip (3). 3. Connect the sensor electrical connector (1). 4. Install the sending unit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Pressure Sensor > Component Information > Locations Fuel Pressure Sensor: Locations Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Pressure Sensor > Component Information > Locations > Page 4280 Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Pressure Sensor > Component Information > Locations > Page 4281 Fuel Pressure Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Pressure Sensor > Component Information > Locations > Page 4282 Fuel Pressure Sensor: Service and Repair FUEL RAIL PRESSURE (FRP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet duct. 2. Remove the exhaust gas recirculation (EGR) cooler tube. 3. Disconnect the fuel rail pressure sensor electrical connector. 4. Prior to removal, clean the fuel pressure sensor and surrounding area thoroughly with solvent, such as GM P/N 12377981 (Canadian P/N 10953463) or equivalent. 5. Using compressed air, thoroughly blow dry the sensor and surrounding area. 6. Remove the fuel pressure sensor (1). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Pressure Sensor > Component Information > Locations > Page 4283 1. Install the fuel pressure sensor (1). Tighten Tighten the sensor to 70 N.m (52 lb ft). 2. Connect the fuel rail pressure sensor electrical connector. 3. Install the EGR cooler tube. 4. Install the air cleaner outlet duct. 5. Prime the fuel system. Refer to Fuel System Priming. 6. Start the engine. If the engine stalls, repeat the above step. 7. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Intake Air Temperature (IAT) Sensor: Locations Intake Air Temperature (IAT) Sensor is part of the Mass Air Flow (MAF) Sensor and is in the air induction tube. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 4287 Intake Air Temperature (IAT)/Mass Airflow (MAF) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 4288 Intake Air Temperature (IAT) Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector (1). 2. Remove the MAF/IAT sensor TORX(R) screws. 3. Remove the MAF/IAT sensor (1). INSTALLATION PROCEDURE 1. Install the MAF/IAT sensor (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 4289 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the MAF/IAT sensor TORX(R) screws. Tighten Tighten the screws to 8 N.m (70 lb in). 3. Connect the MAF/IAT sensor electrical connector (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations Oil Level Sensor For ECM: Locations Left Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations > Page 4293 Left Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations > Page 4294 Engine Oil Level Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the left wheelhouse inner panel. Important: Clean the area around the sensor. Do not allow debris to enter the engine. 2. Disconnect the oil pressure sensor electrical connector. 3. Using J 41712, remove the oil pressure sensor (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 4298 Installation Procedure 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 41712, install the oil pressure sensor (1). Tighten the sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector. 4. Install the left wheelhouse inner panel. 5. Check and add engine oil if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start Transmission Position Switch/Sensor: Customer Interest A/T - Slow/No Gear Engagement/Engine No Start Bulletin No.: 02-07-30-011C Date: June 21, 2004 TECHNICAL Subject: Slow or No Engagement of Automatic Transmission, No Start, Blank PRNDL Display, Flashing PRNDL, DTC P0708, P0872, P0847, P0875, P1711, P1713 or U1000 Set (Diagnose Condition, Repair According to Procedure) Models: 2001-2004 Chevrolet Silverado 2001-2004 GMC Sierra with Allison(R) LCT1000 Automatic Transmission (RPO M74) and 6.6L Duramax(TM) Diesel Engine (RPO LB7) or 8.1L Gas Engine (RPO L18) Supercede: This bulletin is being revised to add model years and additional model information and add graphics. Please discard Corporate Bulletin Number 02-07-30-011B (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions. ^ The PRNDL display is flashing. ^ The engine will not start. ^ The "Service Engine Soon" Indicator lamp is illuminated. ^ The transmission does not shift properly. ^ The vehicle will not move, transmission will not engage. Cause Moisture contamination within the Park Neutral Position (PNP) Switch may cause this condition. This is sometimes referred to as the Neutral Start Back-up (NSBU) Switch. On a left turn, water spray from the left front tire is directed directly at this switch. Proper installation of the "Front Shield" and "Rear Shield" are essential for proper repairs. Technician Diagnosis This bulletin ONLY applies to vehicles equipped with a two connector PNP switch as shown above. A complete and through diagnosis must be performed by a qualified electrical technician to determine the cause and avoid needless replacement of good components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 4307 Important: The Transmission Control Module (TCM) and or the Pressure Switch Manifold (PSM) should NOT be replaced unless properly diagnosed. They are probably not the cause of the concern. It is often assumed the module is the cause of the concern when, in fact, it is another component or the wiring between the components that causes the concern. Important: Remember, everything starts with a properly operating Neutral Start Back Up (NSBU) switch. The NSBU switch has been incorporated into what is now called the Park Neutral Position (PNP) switch. If the PNP switch does not provide the proper voltage signal to the module indicating the transmission is in either Park or Neutral, the module will not allow the starter operation. After the engine is started, and the shift lever is moved to either Reverse or one of the drive positions, the range selected portion of the PNP switch portion provides a voltage input to the module as to what range the driver has manually selected for transmission operation. The module then controls pressures, shift points and other transmission functions based on the voltage input received from the range portion of the PNP switch. The technician may find one or more of the following conditions. The list of these conditions does not imply any type of frequency or order. They are random events and may occur in any order. ^ DTC P0708, Neutral start/backup (PNP or NSBU) switch ^ DTC P0847, Pressure Switch Manifold (PSM) ^ DTC P0872, Pressure Switch Manifold (PSM) ^ DTC P0875, Pressure Switch Manifold (PSM) ^ DTC P1711, Pressure Switch Manifold (PSM) ^ DTC P1713, Pressure Switch Manifold (PSM) ^ DTC U1000, Serial Data Communications ^ Blank PRNDL Display ^ Flashing PRNDL Display ^ Slow or No Engagement of Automatic Transmission Blank PRNDL Display A blank PRNDL display may indicate a condition with the PNP switch and/or one or more of the four signal circuits from the PNP to the TCM. 1. Pin A, Circuit 771 (BLK/WHT) 2. Pin B, Circuit 773 (GRA) 3. Pin C, Circuit 776 (WHT) 4. Pin D, Circuit 772 (YEL) Or, a blank PRNDL display may also occur if an out of line condition exists with the Serial Data Circuit (CKT 2470, yellow wire) from the TCM to Splice Pack 205. Diagnostic Tip 1. Connect the Tech 2(R) to the vehicle. 2. Power up the Tech 2(R). 3. Does the Tech 2(R) communicate with the TCM? If not, inspect the serial data circuit, CKT 2470 (Yellow wire), between the TCM and Splice Pack 205. Specifically inspect connector C106, a five terminal connector located below the left side underhood bussed electrical center, directly beneath the red battery cable terminal connection. Perform a mating terminal pull test on all of the terminals in this connector. Repair as required. 4. Observe the Gear Selected screen on the scan tool. The following values should be shown on the Tech 2(R) display and the vehicle's instrument panel cluster (if equipped with the I/P display). ^ "8" (shifter should be in the Park position) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 4308 ^ "7" (shifter should be in the Reverse position) ^ "5" (shifter should be in the Drive position) ^ "3" (shifter should be in the Third gear position) ^ "2" (shifter should be in the Second gear position) ^ "1" (shifter should be in the First gear position) ^ "0" (shifter should be in the Neutral Position) If the Gear Selected display does not match the shifter position in the vehicle, diagnose using one of the following methods. ^ Obtain a new PNP switch kit, P/N 29540479, from the Parts Department. ^ 0.1. Disconnect the wiring connector from the original transmission mounted PNP switch. ^ 0.2. Connect the new switch to the wiring connector. ^ 0.3. Return to Step # 4 above and observe the display as you rotate the switch. If all positions indicate properly, refer to the Correction section below. ^ Use the DTC P0708 diagnostic chart in Service Information (SI) under Transmission/Transaxle/Automatic Transmission - Allison. Reference SI Document ID # 769549 for the wiring schematic for this symptom. The PNP switch, as referenced in SI, is known as the NSBU switch in the Parts information. It is now serviced with a Park Neutral Position Switch Kit, P/N 29540479. Flashing PRNDL Display A flashing PRNDL display may be the result of incorrect sensor inputs or transmission abuse protection modes being received by the TCM. The following are some of these conditions: ^ The transfer case is/was in Neutral. ^ The transfer case is/was shifted into Neutral when the vehicle is moving. ^ A decrease of the input turbine speed was not detected when the gear selector was moved into any gear. ^ A low transmission fluid level. ^ A misadjusted PNP/NSBU switch. ^ Turbine input speed or output speed sensor failure. ^ Failures of the shift solenoids to route the transmission oil to the proper clutch assemblies within the transmission. ^ Failures of the transmission clutch packs (C1 or C5 for first gear, C3 or C5 for Reverse). ^ Failure to detect proper line pressures when a gear range is selected, which may be the result of normal maintenance such as a transmission fluid change having been completed, or the transmission pan was removed for a filter replacement or other type service. Transmission abuse protection modes are encountered when a customer performs one of the following types of maneuvers: ^ Shifting from Neutral to Drive/Reverse when the engine RPM is greater than 1400 RPM. ^ Shifting from Drive to Reverse when the throttle position (TPS) is greater than 25%, such as rocking the vehicle when stuck in an attempt to free the vehicle. ^ When the transmission output speed is greater than 300 RPM from attempted changes in direction such as Reverse to Drive, Drive to Reverse or Neutral to Reverse shifts. When the TCM encounters any one of the above conditions, the TCM will flash the PRNDL and default the transmission to Neutral. A flashing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 4309 PRNDL indicates something is/was incorrect. The transmission may need the attention of a qualified service technician. Correction 1. Disconnect the wiring harness from the PNP switch. 2. Disconnect the shift linkage/cable from the shift lever at the transmission. 3. With a wrench keeping the shift lever from rotating, remove the nut from the end of the selector shaft. 4. Use a file to remove any burrs or raised metal where the selector lever was seated against the shoulder of the selector shaft. Important: If the old PNP switch will not slide from the selector shaft without the effort, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 5. Remove the two bolts that attach the PNP switch and remove the switch by sliding it outward over the selector shaft. 6. Make sure the selector shaft is in the N (neutral) position (using a wrench on the selector shaft flats, rotate the shaft to its furthest clockwise position and then rotate counterclockwise two detents). Important: If the new PNP switch will not slide onto the selector shaft easily, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 7. Slide the new PNP switch over the selector shaft with the neutral assurance bracket 920 facing outward and maintaining the correct PNP switch orientation to the selector shaft. Install and hand tighten the two PNP switch attaching bolts so that the PNP switch and bracket may be rotated within the adjusting slots with some effort. 8. While holding the neutral assurance bracket in engagement with the PNP switch, tighten the two bolts that attach the PNP switch to the transmission case. Tighten Tighten the bolts to 27 N.m (20 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 4310 9. Remove and discard the neutral assurance bracket. Important: Installation of the front shield and rear shields are important. Without proper installation of the shield, a return repair is probable. Follow all directions as listed on the installation instructions sheet included in the Switch kit, P/N 29540479. 10. Fit the new shield onto the PNP switch so that it fits securely against the switch. Make sure this is done before reinstalling the shift lever. 11. Reinstall the shift lever. With a wrench keeping the shift lever from rotating, install the nut on the end of the selector shaft. Tighten. Tighten the nut to 24 N.m (18 lb ft). 12. Connect the wiring harness connectors to the PNP switch. 13. Attach the selector cable to the lever. Check and adjust if needed. 14. Go back to step 4 of the Diagnostics and insure the Tech 2 readings match the shift lever positions. Important: Clear all DTCs before returning the vehicle to the customer. 15. Return the vehicle to the customer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 4311 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Slow/No Gear Engagement/Engine No Start Bulletin No.: 02-07-30-011C Date: June 21, 2004 TECHNICAL Subject: Slow or No Engagement of Automatic Transmission, No Start, Blank PRNDL Display, Flashing PRNDL, DTC P0708, P0872, P0847, P0875, P1711, P1713 or U1000 Set (Diagnose Condition, Repair According to Procedure) Models: 2001-2004 Chevrolet Silverado 2001-2004 GMC Sierra with Allison(R) LCT1000 Automatic Transmission (RPO M74) and 6.6L Duramax(TM) Diesel Engine (RPO LB7) or 8.1L Gas Engine (RPO L18) Supercede: This bulletin is being revised to add model years and additional model information and add graphics. Please discard Corporate Bulletin Number 02-07-30-011B (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions. ^ The PRNDL display is flashing. ^ The engine will not start. ^ The "Service Engine Soon" Indicator lamp is illuminated. ^ The transmission does not shift properly. ^ The vehicle will not move, transmission will not engage. Cause Moisture contamination within the Park Neutral Position (PNP) Switch may cause this condition. This is sometimes referred to as the Neutral Start Back-up (NSBU) Switch. On a left turn, water spray from the left front tire is directed directly at this switch. Proper installation of the "Front Shield" and "Rear Shield" are essential for proper repairs. Technician Diagnosis This bulletin ONLY applies to vehicles equipped with a two connector PNP switch as shown above. A complete and through diagnosis must be performed by a qualified electrical technician to determine the cause and avoid needless replacement of good components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 4317 Important: The Transmission Control Module (TCM) and or the Pressure Switch Manifold (PSM) should NOT be replaced unless properly diagnosed. They are probably not the cause of the concern. It is often assumed the module is the cause of the concern when, in fact, it is another component or the wiring between the components that causes the concern. Important: Remember, everything starts with a properly operating Neutral Start Back Up (NSBU) switch. The NSBU switch has been incorporated into what is now called the Park Neutral Position (PNP) switch. If the PNP switch does not provide the proper voltage signal to the module indicating the transmission is in either Park or Neutral, the module will not allow the starter operation. After the engine is started, and the shift lever is moved to either Reverse or one of the drive positions, the range selected portion of the PNP switch portion provides a voltage input to the module as to what range the driver has manually selected for transmission operation. The module then controls pressures, shift points and other transmission functions based on the voltage input received from the range portion of the PNP switch. The technician may find one or more of the following conditions. The list of these conditions does not imply any type of frequency or order. They are random events and may occur in any order. ^ DTC P0708, Neutral start/backup (PNP or NSBU) switch ^ DTC P0847, Pressure Switch Manifold (PSM) ^ DTC P0872, Pressure Switch Manifold (PSM) ^ DTC P0875, Pressure Switch Manifold (PSM) ^ DTC P1711, Pressure Switch Manifold (PSM) ^ DTC P1713, Pressure Switch Manifold (PSM) ^ DTC U1000, Serial Data Communications ^ Blank PRNDL Display ^ Flashing PRNDL Display ^ Slow or No Engagement of Automatic Transmission Blank PRNDL Display A blank PRNDL display may indicate a condition with the PNP switch and/or one or more of the four signal circuits from the PNP to the TCM. 1. Pin A, Circuit 771 (BLK/WHT) 2. Pin B, Circuit 773 (GRA) 3. Pin C, Circuit 776 (WHT) 4. Pin D, Circuit 772 (YEL) Or, a blank PRNDL display may also occur if an out of line condition exists with the Serial Data Circuit (CKT 2470, yellow wire) from the TCM to Splice Pack 205. Diagnostic Tip 1. Connect the Tech 2(R) to the vehicle. 2. Power up the Tech 2(R). 3. Does the Tech 2(R) communicate with the TCM? If not, inspect the serial data circuit, CKT 2470 (Yellow wire), between the TCM and Splice Pack 205. Specifically inspect connector C106, a five terminal connector located below the left side underhood bussed electrical center, directly beneath the red battery cable terminal connection. Perform a mating terminal pull test on all of the terminals in this connector. Repair as required. 4. Observe the Gear Selected screen on the scan tool. The following values should be shown on the Tech 2(R) display and the vehicle's instrument panel cluster (if equipped with the I/P display). ^ "8" (shifter should be in the Park position) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 4318 ^ "7" (shifter should be in the Reverse position) ^ "5" (shifter should be in the Drive position) ^ "3" (shifter should be in the Third gear position) ^ "2" (shifter should be in the Second gear position) ^ "1" (shifter should be in the First gear position) ^ "0" (shifter should be in the Neutral Position) If the Gear Selected display does not match the shifter position in the vehicle, diagnose using one of the following methods. ^ Obtain a new PNP switch kit, P/N 29540479, from the Parts Department. ^ 0.1. Disconnect the wiring connector from the original transmission mounted PNP switch. ^ 0.2. Connect the new switch to the wiring connector. ^ 0.3. Return to Step # 4 above and observe the display as you rotate the switch. If all positions indicate properly, refer to the Correction section below. ^ Use the DTC P0708 diagnostic chart in Service Information (SI) under Transmission/Transaxle/Automatic Transmission - Allison. Reference SI Document ID # 769549 for the wiring schematic for this symptom. The PNP switch, as referenced in SI, is known as the NSBU switch in the Parts information. It is now serviced with a Park Neutral Position Switch Kit, P/N 29540479. Flashing PRNDL Display A flashing PRNDL display may be the result of incorrect sensor inputs or transmission abuse protection modes being received by the TCM. The following are some of these conditions: ^ The transfer case is/was in Neutral. ^ The transfer case is/was shifted into Neutral when the vehicle is moving. ^ A decrease of the input turbine speed was not detected when the gear selector was moved into any gear. ^ A low transmission fluid level. ^ A misadjusted PNP/NSBU switch. ^ Turbine input speed or output speed sensor failure. ^ Failures of the shift solenoids to route the transmission oil to the proper clutch assemblies within the transmission. ^ Failures of the transmission clutch packs (C1 or C5 for first gear, C3 or C5 for Reverse). ^ Failure to detect proper line pressures when a gear range is selected, which may be the result of normal maintenance such as a transmission fluid change having been completed, or the transmission pan was removed for a filter replacement or other type service. Transmission abuse protection modes are encountered when a customer performs one of the following types of maneuvers: ^ Shifting from Neutral to Drive/Reverse when the engine RPM is greater than 1400 RPM. ^ Shifting from Drive to Reverse when the throttle position (TPS) is greater than 25%, such as rocking the vehicle when stuck in an attempt to free the vehicle. ^ When the transmission output speed is greater than 300 RPM from attempted changes in direction such as Reverse to Drive, Drive to Reverse or Neutral to Reverse shifts. When the TCM encounters any one of the above conditions, the TCM will flash the PRNDL and default the transmission to Neutral. A flashing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 4319 PRNDL indicates something is/was incorrect. The transmission may need the attention of a qualified service technician. Correction 1. Disconnect the wiring harness from the PNP switch. 2. Disconnect the shift linkage/cable from the shift lever at the transmission. 3. With a wrench keeping the shift lever from rotating, remove the nut from the end of the selector shaft. 4. Use a file to remove any burrs or raised metal where the selector lever was seated against the shoulder of the selector shaft. Important: If the old PNP switch will not slide from the selector shaft without the effort, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 5. Remove the two bolts that attach the PNP switch and remove the switch by sliding it outward over the selector shaft. 6. Make sure the selector shaft is in the N (neutral) position (using a wrench on the selector shaft flats, rotate the shaft to its furthest clockwise position and then rotate counterclockwise two detents). Important: If the new PNP switch will not slide onto the selector shaft easily, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 7. Slide the new PNP switch over the selector shaft with the neutral assurance bracket 920 facing outward and maintaining the correct PNP switch orientation to the selector shaft. Install and hand tighten the two PNP switch attaching bolts so that the PNP switch and bracket may be rotated within the adjusting slots with some effort. 8. While holding the neutral assurance bracket in engagement with the PNP switch, tighten the two bolts that attach the PNP switch to the transmission case. Tighten Tighten the bolts to 27 N.m (20 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 4320 9. Remove and discard the neutral assurance bracket. Important: Installation of the front shield and rear shields are important. Without proper installation of the shield, a return repair is probable. Follow all directions as listed on the installation instructions sheet included in the Switch kit, P/N 29540479. 10. Fit the new shield onto the PNP switch so that it fits securely against the switch. Make sure this is done before reinstalling the shift lever. 11. Reinstall the shift lever. With a wrench keeping the shift lever from rotating, install the nut on the end of the selector shaft. Tighten. Tighten the nut to 24 N.m (18 lb ft). 12. Connect the wiring harness connectors to the PNP switch. 13. Attach the selector cable to the lever. Check and adjust if needed. 14. Go back to step 4 of the Diagnostics and insure the Tech 2 readings match the shift lever positions. Important: Clear all DTCs before returning the vehicle to the customer. 15. Return the vehicle to the customer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 4321 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4322 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4323 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 4326 Transmission Position Switch/Sensor: Adjustments Automatic Transmission - Allison Park/Neutral Position Switch Adjustment ^ Tools Required J 41364-A PNP Switch Adjusting Tool Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Make sure the selector shaft is in the N (Neutral) position as follows: ^ Place a wrench on the selector shaft flats and rotate the shaft to its furthest clockwise position. ^ Rotate the selector shaft counter-clockwise two detents. 2. Be sure that J 41364-A (2) is in the proper position on PNP switch (1). 3. While maintaining the correct PNP switch-to-selector-shaft alignment, slide the new PNP switch (5) over the selector shaft (4). 4. Notice: Refer to Component Fastener Tightening Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 4327 While holding J 41364-A in engagement with the PNP switch, install the two bolts (6) so that the PNP switch may be rotated with some effort. ^ Tighten the two bolts (6) to 27 Nm (20 ft. lbs.). 5. Remove J 41364-A. 6. Install splash shield (1), concave side toward PNP switch (3), over selector shaft (2). 7. Notice: Refer to Transmission Selector Shaft Abuse Notice in Service Precautions. Reinstall Shift Lever (2). Install nut (3), by hand, on the end of selector shaft (4). Use a wrench (1) to keep the shift lever from rotating. ^ Tighten nut (3) to 24 Nm (18 ft. lbs.) 8. Reconnect the shift selector linkage/cable to the shift lever (2). 9. Connect the external wiring harness to the PNP switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L80-E/4L85-E Park/Neutral Position Switch Replacement Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 4330 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 4331 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 4332 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Park Lock Pawl and Actuator Replacement Park Lock Pawl and Actuator Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the park/neutral position (PNP) switch. 3. Remove the manual shaft nut and pin. 4. Remove the detent lever and actuator. 5. Remove the parking pawl bracket bolts. 6. Remove the parking pawl return spring. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 4333 7. Use the modified screw extractor in order to remove the plug. 8. Remove the parking pawl shaft retainer, shaft and pawl. 9. Important: If the manual shaft binds in the case during removal, file or sand the shaft in the area adjacent to the detent lever. Remove the manual shaft. 10. Remove the manual shaft seal. Installation Procedure 1. Install the pawl shaft. 2. Install the parking pawl. 3. Install the plug using a 8 mm or (5/16 inch) rod with Loctite® or equivalent. 4. Install the retainer. 5. Install the pawl return spring. 6. Install the detent lever to the actuator. 7. Install the actuator over the parking pawl. 8. Install the manual shaft seal. 9. Lubricate the manual shaft with transmission oil and install the manual shaft into the case. 10. Install the nut on the shaft. 11. Install the roll pin. 12. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 4334 Install the parking lock bracket bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 13. Install the PNP switch. 14. Install the transmission filter. 15. Fill the transmission to the proper level with Dexron® III transmission fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 4335 Transmission Position Switch/Sensor: Service and Repair Automatic Transmission - Allison Park/Neutral Position Switch Replacement PNP Switch Removal Refer to Park/Neutral Position Switch Removal. PNP Switch Install Refer to Park/Neutral Position Switch Installation. 7. Notice: Refer to Transmission Selector Shaft Abuse Notice in Service Precautions. Reinstall shift lever (2). Install nut (3), by hand, on the end of selector shaft (4). Use a wrench (1) to keep the shift lever from rotating. ^ Tighten nut (3) to 24 Nm (18 ft. lbs.). 8. Reconnect the shift selector linkage/cable to the shift lever (2). 9. Connect the external wiring harness to the PNP switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > A/T - Shifting/Poor Performance Vehicle Speed Sensor: Technical Service Bulletins A/T - Shifting/Poor Performance INFORMATION Bulletin No.: 01-03-10-010G Date: July 22, 2009 Subject: Inspection of Tire and Wheel Size Prior to Diagnosis of Transmission Shifts, Poor Performance, Speedometer, Cruise Control Concerns Models: 2001-2007 Chevrolet Silverado Pickup (Classic) Models Equipped with Allison(R) Automatic Transmission Only 2001-2007 GMC Sierra Pickup (Classic) Models Equipped with Allison(R) Automatic Transmission Only 2007-2010 Chevrolet Silverado Pickup HD Models 2007-2010 GMC Sierra Pickup HD Models Supercede: This bulletin is being revised to add the 2008-2010 model years, update the tire size information and reference the vehicle tire information label locations. Please discard Corporate Bulletin Number 01-03-10-010F (Section 03 - Suspension). GM has developed and matched specific tires for your vehicle. The original equipment tires and their respective size installed on the vehicle when it was new, were designed to meet General Motors Tire Performance Criteria Specification (TPC Spec) system rating. GM's exclusive TPC Spec system considers over a dozen critical specifications that impact the overall performance of the vehicle. A truck that has different tires and wheels from the original equipment designed for that vehicle will have engine power/performance concerns, transmission shift concerns, speedometer registered speed concerns, cruise control concerns and increased steering effort, especially during parking lot maneuvers at slow speeds. The engine control module (ECM) and transmission control module (TCM) use engine speed (RPM) and vehicle speed sensor (VSS) inputs as operational parameters for engine torque, transmission shifting, cruise control operation and speedometer indicated vehicle speed. Calibrations for different tire/wheel combinations are not available. Therefore, changing of tire and/or wheel size should not be undertaken by dealerships or truck owners. Proper diagnosis of engine, transmission, speedometer and cruise control concerns MUST begin with an inspection of tire/wheel size. Important A vehicle specific Tire and Loading Information label is attached to the center pillar (B-pillar) of the vehicle. With the driver's door open, you will find the label attached below the door lock post (striker). The label shows the size of the original equipment tires and the recommended cold tire inflation pressures.A vehicle specific Certification/Tire label is found on the rear edge of the driver's door. The label shows the size of the original equipment tires and the recommended cold tire inflation pressures. 2001-2007 Pickups (Classic) Equipped with Allison(R) Automatic Transmission Only Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT215/85R16D tires as standard equipment. 2007 Pickups HD Models (New Design Pickups) Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT215/85R16E tires as standard equipment. 2008-2010 Pickups HD Models (New Design Pickups) Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > A/T - Shifting/Poor Performance > Page 4340 - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT225/75R17E tires as standard equipment. If a truck is found to have other than the above listed tire sizes, no further diagnosis should be undertaken until the original size tires and wheels are reinstalled on the truck. Warranty Information Reinstalling the proper wheels and tires on the vehicle, prior to performing any type of diagnosis of the truck, would be considered truck owner responsibility and not a warranty repair. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Vehicle Speed Sensor (VSS) Vehicle Speed Sensor: Diagrams Vehicle Speed Sensor (VSS) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Vehicle Speed Sensor (VSS) > Page 4343 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Vehicle Speed Sensor (VSS) > Page 4344 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 Vehicle Speed Sensor: Service and Repair Manual Transmission - NV 3500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 4347 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and O-ring seal. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 4348 Vehicle Speed Sensor: Service and Repair Manual Transmission - NV 4500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (3). 3. Remove the VSS and seal. Installation Procedure 1. Coat the NEW O-ring seal with a thin film of transmission fluid, use GM P/N 12346190 (Canadian P/N 10953477), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 4349 3. Connect the VSS electrical connector (3). Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 4350 Vehicle Speed Sensor: Service and Repair Manual Transmission - ZF S6-650 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped with the 6.6L engine, disconnect the vehicle speed sensor (VSS) electrical connector (4). 3. If equipped with the 8.1L engine, disconnect the VSS electrical connector (5). 4. Remove the VSS bolt, sensor and seal. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 4351 1. Lubricate a NEW O-ring seal with transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). 3. If equipped with the 8.1L engine, connect the VSS electrical connector (5). 4. If equipped with the 6.6L engine, connect the VSS electrical connector (4). 5. Lower the vehicle. 6. Check the transmission fluid level. Add if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 4352 Vehicle Speed Sensor: Service and Repair Automatic Transmission - 4L60-E/4L65-E Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). 4. Notice: Refer to Fastener Notice in Service Precautions. Install the VSS bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 4353 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4358 Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4359 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SYSTEM DESCRIPTION The accelerator pedal position (APP) system along with the vehicle electronics and components is used to calculate and control the amount of acceleration and deceleration via fuel injector control. This eliminates the need for a mechanical cable attachment from the accelerator pedal to a throttle body. The APP system includes, but is not limited to, the following components : - The accelerator pedal position (APP) sensor assembly - The engine control module (ECM) Accelerator Pedal Position (APP) Sensor The accelerator pedal position (APP) sensor is mounted on the accelerator pedal control assembly. The sensor is made up of 3 individual sensors within one housing. Three separate signal, low reference, and 5-volt reference circuits are used in order to interface the accelerator pedal sensor assembly with the ECM. Each sensor has a unique functionality to determine pedal position. The ECM uses the APP sensor to determine the amount of acceleration or deceleration desired by the person driving the vehicle. The APP sensor 1 voltage should increase as the accelerator pedal is depressed, from below 1.0 volt at 0 pedal travel to above 2 volts at 100 percent pedal travel. APP sensor 2 voltage should decrease from above 4 volts at 0 pedal travel to below 3.0 volts at 100 percent pedal travel. APP sensor 3 voltage should decrease from above 3.8 volts at 0 percent pedal travel to below 3.3 volts at 100 percent pedal travel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4360 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION (APP) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector. 3. Reposition the carpet to access the lower nut. 4. Remove the accelerator pedal nuts. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4361 1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Service Precautions. 2. Install the accelerator pedal nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Connect the APP sensor electrical connector. 4. Reposition the carpet. 5. Install the CPA retainer. 6. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 7. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle and a wide open throttle (WOT). 8. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 9. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Mass Air Flow (MAF) Sensor: Locations Right Side Of The Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4365 Right Side Of Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4366 Intake Air Temperature (IAT)/Mass Airflow (MAF) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4367 Mass Air Flow (MAF) Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector (1). 2. Remove the MAF/IAT sensor TORX(R) screws. 3. Remove the MAF/IAT sensor (1). INSTALLATION PROCEDURE 1. Install the MAF/IAT sensor (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4368 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the MAF/IAT sensor TORX(R) screws. Tighten Tighten the screws to 8 N.m (70 lb in). 3. Connect the MAF/IAT sensor electrical connector (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations Control Module: Service and Repair Transmission Control Module Replacement Transmission Control Module (TCM) Replacement Removal Procedure Important: ^ Remove any debris from the transmission control module(TCM) connector surfaces before servicing the TCM. Inspect the TCM module connector gaskets when diagnosing or replacing the TCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the TCM. ^ The ignition must be OFF when disconnecting or reconnecting power to the TCM. 1. Disconnect the negative battery cable. 2. Remove the TCM cover bolts (1) located on the left side of the radiator shroud. 3. Pull the cover and TCM up and away from the radiator shroud. 4. Push up on the retainers (1) in order to remove the TCM from the cover. 5. Disconnect the TCM electrical connectors (2) and remove the TCM from the vehicle. Installation Procedure 1. Connect the TCM electrical connectors (2) to the TCM. 2. Install the TCM to the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 4372 3. Using the alignment tabs (1), install the cover and module to the radiator shroud. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the TCM cover bolts (1) to the radiator shroud. ^ Tighten the bolts to 9 Nm (80 inch lbs.). 5. Connect the negative battery cable. 6. Reprogram the TCM. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 4373 Control Module: Service and Repair Transmission Control Module Reprogramming Procedures Transmission Control Module Reprogramming Procedures Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install new module before proceeding. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the Electronic Control Unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to Program/Reprogram. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Reconnect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the Electronic Control Unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to Program/Reprogram. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 4374 Gear Sensor/Switch: Service and Repair Encoder Motor Sensor Replacement Removal Procedure Important: For ease of reassembly, shift the transfer case to 2HI prior to removing any components. 1. Remove the encoder motor. 2. Place the encoder motor on a clean work bench, 3. Remove the 2 screws (2) from the motor cover. 4. Remove the 2 screws (1) from the casting. 5. Remove the cover. 6. Remove and save the shim on the output gear. 7. Remove and discard the orange rubber seal from the cover. 8. Remove the output gear (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 4375 9. Disassemble the harness connector (1) from the encoder. 10. Remove the encoder from the output shaft using a flat tip screwdriver. Installation Procedure 1. Assemble the harness to the NEW encoder with the connector legend "TOP" (1) and the encoder part number facing up. 2. Assemble the output shaft into the encoder, being sure to align the encoder tab with the groove on the shaft. 3. Ensure the encoder is seating properly on the output gear. 4. Place the output shaft encoder on the casting. 5. Place the grommet harness on the casting slot, the flat area on the grommet will be facing up. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 4376 6. With the output gear encoder assembly in hand, carefully align the casting and output gear timing marks (1). 7. At the same time, be sure to align the encoder phasing post (1) with the phasing slot (2) in the casting and insert the shaft into the bushing. 8. Verify that the output gear and idler are engaged properly. 9. Seat the harness wires on the casting channel. 10. Place the shim on the output shaft gear. 11. Press a NEW seal into the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 4377 12. Install the cover. Notice: Refer to Fastener Notice in Service Precautions. 13. Install 2 NEW screws (1) to the casting. ^ Tighten the screws to 2 Nm (18 inch lbs.). 14. Install 2 NEW longer screws (2) to the motor cover. ^ Tighten the screws to 3 Nm (26 inch lbs.). 15. Install the encoder motor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations Turbo Boost Sensor: Locations Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Page 4381 Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Page 4382 Boost Pressure Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Page 4383 Turbo Boost Sensor: Service and Repair BOOST PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the right fuel rail fuel feed pipe. 2. Remove the boost sensor bracket bolt (1). 3. Remove the boost sensor and bracket. 4. Separate the boost sensor from the bracket. 5. Inspect the sensor seal for damage, replace as necessary. INSTALLATION PROCEDURE 1. Position the boost sensor onto the bracket. 2. Install the boost sensor and bracket. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the boost sensor bracket bolt (1). Tighten Tighten the bolt to 9 N.m (80 lb in). 4. Install the right fuel rail fuel feed pipe. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Right Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4388 Camshaft Position (CMP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Replacement CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the cooling fan pulley. 2. Remove the camshaft position (CMP) sensor bolt. 3. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Lubricate the CMP sensor O-ring with clean engine oil. 2. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the CMP sensor bolt. Tighten Tighten the bolt to 10 N.m (89 lb in). 4. Install the cooling fan pulley. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement > Page 4391 Camshaft Position Sensor: Service and Repair Camshaft Reluctor Replacement Camshaft Reluctor Replacement Removal Procedure Notice: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 1. Remove the engine front cover. 2. While holding the secondary oil pump shaft with a hex driver, remove the oil pump driven gear nut. 3. Remove the oil pump driven gear. 4. Important: DO NOT remove the reluctor from the oil pump drive gear. The reluctor is timed to the gear and once removed the correct timing will be lost. Remove the oil pump drive gear and crankshaft sensor reluctor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement > Page 4392 5. Remove the camshaft reluctor screws. 6. Remove the camshaft reluctor. 7. Clean and Inspect the camshaft reluctor for damage. Replace the reluctor if damage is found. Installation Procedure 1. Position the camshaft reluctor to the camshaft gear. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the camshaft reluctor bolts. Tighten the bolts to 9 Nm (80 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement > Page 4393 3. Important: Do not damage the teeth on the reluctor. Install the oil pump drive gear and reluctor to the crankshaft. 4. Install the oil pump driven gear. 5. While holding the secondary oil pump shaft with a hex driver, install the oil pump driven gear nut. Tighten the nut to 100 Nm (74 ft. lbs.). 6. Install the engine front cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Starter Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4397 Right Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4398 Crankshaft Position (CKP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4399 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the right wheelhouse panel. 3. Disconnect the crankshaft position (CKP) sensor electrical connector. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. 6. If necessary, remove the CKP sensor spacer bolts. 7. If necessary, remove the CKP sensor spacer. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4400 1. If necessary, lubricate a NEW CKP spacer O-ring with clean engine oil. 2. If necessary, install the NEW O-ring to the CKP sensor spacer. IMPORTANT: The crankshaft position sensor spacers are machined with different timing positions. However, if the crankshaft position sensor spacer requires replacement, replace with a grade "C" spacer. 3. If necessary, install the CKP sensor spacer. NOTE: Refer to Fastener Notice in Service Precautions. 4. If necessary, install the CKP sensor spacer bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). 5. Lubricate a NEW CKP sensor O-ring with clean engine oil. 6. Install the NEW O-ring to the CKP sensor. 7. Install the CKP sensor. 8. Install the CKP sensor bolt. Tighten Tighten the bolt to 10 N.m (89 lb in). 9. Connect the CKP sensor electrical connector. 10. Install the right wheelhouse panel. 11. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Temperature Sensor: Locations Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations > Page 4406 Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information Not Supplied By The Manufacturer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Air Cleaner Fresh Air Duct/Hose: Customer Interest Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4419 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4420 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4421 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4422 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4423 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4424 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4425 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Air Cleaner Fresh Air Duct/Hose: All Technical Service Bulletins Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4431 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4432 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4433 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4434 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4435 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4436 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4437 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH Catalytic Converter: All Technical Service Bulletins Exhaust System - Moan/Vibration at 55-60 MPH Bulletin No.: 05-06-05-002 Date: July 27, 2005 TECHNICAL Subject: Exhaust Moan/Vibration (Replace Converter Assembly and Exhaust Muffler Assembly) Models: 2004-2005 Chevrolet Silverado 2500HD/3500HD Series Crew Cab Short Box Pickups 2004-2005 GMC Sierra 2500HD/3500HD Series Crew Cab Short Box Pickups with 6.6L Diesel Engine (VIN 2 - RPO LLY) Condition Some customers may comment on a moan or vibration at vehicle speeds approximately 87-97 km/h (55-60 mph) and at approximately 1700-1800 RPM. Correction Replace the catalytic converter assembly and exhaust muffler assembly using the procedure listed below. 1. Raise and suitably support the vehicle. 2. Remove the spare tire. 3. Install adjustable jack stands under the rear axle. 4. Remove the rear axle vent hose from the rear axle. 5. Remove the vent hose swivel clip from the rear brake crossover pipe. 6. Remove the rear shock absorbers lower bolts and nuts. 7. Lower the rear axle using the adjustable jack stands. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 4443 8. Loosen the catalytic converter coupling nuts. 9. With the aid of an assistant, support the exhaust muffler. 10. Gently pry up the catalytic converter coupling clip (1) (on the muffler end) in order to disengage the locator button (3) from the coupling clip. 11. With the aid of an assistant, slide the muffler rearward until the locator button is fully disengaged. 12. Remove the insulators from the frame hangers. 13. With the aid of an assistant, remove the muffler assembly from the vehicle. 14. Support the transmission with a suitable transmission jack. 15. Remove the transmission mount to transmission support nuts. 16. Raise the transmission off of the transmission support. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 4444 17. Remove the transmission support crossmember bolts. 18. Remove the transmission support crossmember. 19. Loosen the exhaust pipe clamp. 20. Slide the exhaust pipe clamp up onto the exhaust pipe. 21. Slide the catalytic converter hanger out of the insulator. 22. Remove the catalytic converter. 23. Apply water based lubricant to the exhaust pipe hanger bracket, in order to aid in installation. 24. Slide the catalytic converter hanger into the insulator. Important: Ensure that the manifold pipe is square to the exhaust pipe adapter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 4445 25. Slide the exhaust pipe clamp down and around the pipe connection. 26. Tighten the exhaust pipe clamp. Tighten Tighten the clamp to 40 N.m (30 lb ft). 27. Lower the transmission onto the transmission support. 28. Install the transmission mount to transmission support nuts. Tighten Tighten the bolts to 40 N.m (30 lb ft). 29. Remove the support from the transmission. 30. With the aid of an assistant, align the new muffler, locator button (3) to the catalytic converter coupling groove (2). 31. Install the muffler until the locator button is fully engaged by the coupling clip (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 4446 Important: Apply lubricant to the insulators to aid in installation. 32. Install the insulators to the frame hangers. 33. Tighten the catalytic converter coupling nuts until snug. 34. Once sung, tighten the catalytic converter coupling nuts. Tighten Tighten the nuts to 45 Nm (33 lb-ft.). 35. Raise the rear axle using the adjustable jack stands. 36. Install the rear shock absorbers lower bolts and nuts. Tighten Tighten the bolts to 95 N.m (70 lb ft). 37. Install the rear axle vent hose to the rear axle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 4447 38. Connect the vent hose swivel clip to the rear brake crossover pipe. 39. Remove the adjustable jack stands from under the rear axle. 40. Install the spare tire. 41. Lower the vehicle. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 4453 8. Loosen the catalytic converter coupling nuts. 9. With the aid of an assistant, support the exhaust muffler. 10. Gently pry up the catalytic converter coupling clip (1) (on the muffler end) in order to disengage the locator button (3) from the coupling clip. 11. With the aid of an assistant, slide the muffler rearward until the locator button is fully disengaged. 12. Remove the insulators from the frame hangers. 13. With the aid of an assistant, remove the muffler assembly from the vehicle. 14. Support the transmission with a suitable transmission jack. 15. Remove the transmission mount to transmission support nuts. 16. Raise the transmission off of the transmission support. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 4454 17. Remove the transmission support crossmember bolts. 18. Remove the transmission support crossmember. 19. Loosen the exhaust pipe clamp. 20. Slide the exhaust pipe clamp up onto the exhaust pipe. 21. Slide the catalytic converter hanger out of the insulator. 22. Remove the catalytic converter. 23. Apply water based lubricant to the exhaust pipe hanger bracket, in order to aid in installation. 24. Slide the catalytic converter hanger into the insulator. Important: Ensure that the manifold pipe is square to the exhaust pipe adapter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 4455 25. Slide the exhaust pipe clamp down and around the pipe connection. 26. Tighten the exhaust pipe clamp. Tighten Tighten the clamp to 40 N.m (30 lb ft). 27. Lower the transmission onto the transmission support. 28. Install the transmission mount to transmission support nuts. Tighten Tighten the bolts to 40 N.m (30 lb ft). 29. Remove the support from the transmission. 30. With the aid of an assistant, align the new muffler, locator button (3) to the catalytic converter coupling groove (2). 31. Install the muffler until the locator button is fully engaged by the coupling clip (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 4456 Important: Apply lubricant to the insulators to aid in installation. 32. Install the insulators to the frame hangers. 33. Tighten the catalytic converter coupling nuts until snug. 34. Once sung, tighten the catalytic converter coupling nuts. Tighten Tighten the nuts to 45 Nm (33 lb-ft.). 35. Raise the rear axle using the adjustable jack stands. 36. Install the rear shock absorbers lower bolts and nuts. Tighten Tighten the bolts to 95 N.m (70 lb ft). 37. Install the rear axle vent hose to the rear axle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 4457 38. Connect the vent hose swivel clip to the rear brake crossover pipe. 39. Remove the adjustable jack stands from under the rear axle. 40. Install the spare tire. 41. Lower the vehicle. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Page 4458 Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR CLEANER OUTLET DUCT REPLACEMENT REMOVAL PROCEDURE 1. Loosen the outlet duct clamps at the turbocharger and the mass air flow (MAF)/intake air temperature (IAT) sensor. 2. Remove the air cleaner outlet duct. INSTALLATION PROCEDURE IMPORTANT: The air cleaner outlet duct must be fully seated against the positive stop feature on the turbocharger inlet. 1. Install the air cleaner outlet duct. NOTE: Refer to Fastener Notice in Service Precautions. 2. Tighten the outlet duct clamps at the turbocharger and the MAF/IAT sensor. Tighten Tighten the clamps to 6 N.m (53 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Restriction Indicator > Component Information > Description and Operation Air Cleaner Restriction Indicator: Description and Operation AIR CLEANER RESTRICTION INDICATOR The air cleaner restriction indicator is located on the air cleaner housing. If the area inside of the clear section is green, no air filter service is required. If the area inside the clear section is orange and Change Air Filter appears, replace the air filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Air Filter Element: Customer Interest Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4470 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4471 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4472 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4473 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4474 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4475 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4476 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 4481 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Air Filter Element: All Technical Service Bulletins Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4487 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4488 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4489 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4490 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4491 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4492 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 4493 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 4498 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 05-00-90-001 > Jan > 05 > Diesel Engine - IMPORTANT Correct Air Filter Usage Air Filter Element: All Technical Service Bulletins Diesel Engine - IMPORTANT Correct Air Filter Usage Bulletin No.: 05-00-90-001 Date: January 05, 2005 INFORMATION Subject: Information on the Proper Air Filter for the Duramax(R) Diesel Models: 2001-2005 Chevrolet Silverado 2001-2005 GMC Sierra with 6.6L Duramax(R) Diesel Engine (VINs 1, 2 - RPOs LB7, LLY) The Duramax(R) air filter, P/N 25332443, is specific to the diesel engine due to the operating characteristics of a turbo charged diesel engine. The turbo allows for a much greater air volume rate than a normal aspirated engine. The Duramax(R) diesel air filter is reinforced to eliminate damage from the increased airflow of the turbo. The reinforcement is visually identified by the five ribs of epoxy that lies across the pleats of the clean side of the filter. If the correct air filter is not used, the filter may collapse or be torn in a Duramax(R) application. This damage will allow dust and dirt to be ingested into the turbo and engine causing serious damage. This damage is usually identified at the turbo vanes as well as extreme wear in the cylinder walls of the engine. There is evidence of gasoline engine air filters being used in the Duaramax(R) application. The 8.1 gas air filter, P/N 25313349, will fit into the air box of the Duramax(R) diesel; however, it does not have the required reinforcement of the diesel air filter. The 8.1 liter gas engine air filter should never be used in a Duramax(R) diesel engine. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 05-00-90-001 > Jan > 05 > Diesel Engine - IMPORTANT Correct Air Filter Usage Air Filter Element: All Technical Service Bulletins Diesel Engine - IMPORTANT Correct Air Filter Usage Bulletin No.: 05-00-90-001 Date: January 05, 2005 INFORMATION Subject: Information on the Proper Air Filter for the Duramax(R) Diesel Models: 2001-2005 Chevrolet Silverado 2001-2005 GMC Sierra with 6.6L Duramax(R) Diesel Engine (VINs 1, 2 - RPOs LB7, LLY) The Duramax(R) air filter, P/N 25332443, is specific to the diesel engine due to the operating characteristics of a turbo charged diesel engine. The turbo allows for a much greater air volume rate than a normal aspirated engine. The Duramax(R) diesel air filter is reinforced to eliminate damage from the increased airflow of the turbo. The reinforcement is visually identified by the five ribs of epoxy that lies across the pleats of the clean side of the filter. If the correct air filter is not used, the filter may collapse or be torn in a Duramax(R) application. This damage will allow dust and dirt to be ingested into the turbo and engine causing serious damage. This damage is usually identified at the turbo vanes as well as extreme wear in the cylinder walls of the engine. There is evidence of gasoline engine air filters being used in the Duaramax(R) application. The 8.1 gas air filter, P/N 25313349, will fit into the air box of the Duramax(R) diesel; however, it does not have the required reinforcement of the diesel air filter. The 8.1 liter gas engine air filter should never be used in a Duramax(R) diesel engine. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 4508 Air Filter Element: Service Precautions NOTE: This information is contained within GM Bulletin 05-00-90-001 dated January 5, 2005. Subject: Information on the Proper Air Filter for the Duramax(R) Diesel Models: 2001-2005 Chevrolet Silverado and GMC Sierra with 6.6L Duramax(R) Diesel Engines (VINs 1, 2 - RPOs LB7, LLY) The Duramax(R) air filter. P/N 25332433, is specific to the diesel engine due to the operating characteristics of a turbocharged diesel engine. The turbo allows for a much greater air volume rate than a normally aspirated engine. The Duramax(R) diesel air filter is reinforced to eliminate damage from the increased airflow of the turbo. The reinforcement is visually identified by the five ribs of epoxy that lie across the pleats of the clean side of the filter. If the correct air filter is not used, the filter may collapse or be torn in a Duramax(R) application. This damage will allow dust and dirt to be ingested into the turbo and engine causing serious damage. This damage is usually identified at the turbo vanes as well as extreme wear in the cylinder walls of the engine. There is evidence of gasoline engine air filters being used in the Duramax(R) application. The 8.1 gas air filter, P/N 25313349 will fit into the air box of the Duramax(R) diesel; however, it does not have the required reinforcement of the diesel air filter. The 8.1 liter gas engine air filter should never be used in a Duramax(R) diesel engine. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 4509 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector (1). 2. Loosen the screws holding the air cleaner housing halves together. 3. Separate the housing halves and remove the air filter element. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 4510 1. Install the air filter element into the lower air cleaner housing. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the upper housing cover and tighten the screws. Tighten Tighten the screws to 4 N.m (35 lb in). 3. Connect the MAF/IAT sensor electrical connector (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Improved Fuel Filter Design Fuel Filter: Technical Service Bulletins Fuel System - Improved Fuel Filter Design INFORMATION Bulletin No.: 04-06-04-070B Date: March 02, 2009 Subject: Information on Improved Fuel Filter for 6.6L Duramax(TM) Diesel Engine Models: 2001-2009 Chevrolet Silverado 2003-2009 Chevrolet Kodiak 2006-2009 Chevrolet Express 2001-2009 GMC Sierra 2003-2009 GMC TopKick 2006-2009 GMC Sierra Equipped with 6.6L Duramax(TM) Diesel Engine (VINs 1, 2, D, 6 - RPOs LB7, LLY, LBZ, LMM) Supercede: This bulletin is being revised to provide additional information to the field on fuel filter applications for the Duramax diesel engine. Please discard Corporate Bulletin Number 04-06-04-070A (Section 06 - Engine/Propulsion System). Important: It is acceptable to use diesel fuel containing up to 5% biodiesel (B5). Higher concentration (i.e., greater than B5) biodiesel-containing fuels or the use of unmodified bio-oils blended into diesel fuel at any concentration is not recommended and could damage the fuel system and engine. Such damage would not be covered by your warranty. A revised fuel filter is released that will service all 2001-2009 Chevrolet and GMC C/K models and 2003-2009 Chevrolet and GMC C4500/5500 Series vehicles with the 6.6L Duramax(TM) Diesel. The new coalescer filter provides the following benefits / improvements over the existing dual pleat design: ^ 150-200% increase in service life, depending on contaminant type Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Improved Fuel Filter Design > Page 4515 ^ Improved fuel system protection with some premium diesel and B5 biodiesel blends ^ Equivalent coarse water droplet removal efficiency of previous design ^ Greatly improved removal of emulsified water - a major contributor to fuel system issues Proper fuel filter servicing and the use of clean diesel fuel that is free of water or contaminants are critical for the longevity of fuel system components of a modern direct injected diesel engine. Adherence to the fuel filter change interval will help to ensure that the Duramax fuel system will be protected from contaminants and that the engine will continue to operate as designed. Purchasing fuel from a high volume fuel retailer increases the chances that the fuel is fresh and of good quality. Parts Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Page 4516 Fuel Filter: Locations FUEL FILTER/HEATER ELEMENT HOUSING Fuel Filter/Heater Element Housing Water In Fuel Sensor The Fuel Filter/Heater Element Housing is located on the right engine rocker cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Page 4517 Fuel Filter: Description and Operation FUEL FILTER The fuel filter is located on the rocker cover. The paper filter element traps particles in the fuel that may damage the fuel injection system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly Fuel Filter: Service and Repair Fuel Filter Assembly FUEL FILTER ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Drain the fuel from the fuel filter. Refer to Water-in-Fuel Draining Procedure. 2. Reposition the fuel hose clamps. 3. Remove the fuel hoses. 4. Disconnect the fuel filter electrical connectors. 5. Remove the fuel filter bracket bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 4520 6. Remove the fuel filter assembly. 7. Remove the fuel filter bracket bolts and bracket from the fuel filter/heater element housing. 8. Remove the fuel filter from the fuel filter/heater element housing. 9. Inspect the fuel filter, replace if necessary. INSTALLATION PROCEDURE 1. Install the fuel filter to the fuel filter/heater element housing. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel filter bracket and bolts to the fuel filter/heater element housing. Tighten Tighten the bolts to 20 N.m (15 lb ft). 3. Install the fuel filter assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 4521 4. Install the fuel filter bracket bolts. Tighten Tighten the bolts to 20 N.m (15 lb ft). 5. Connect the fuel filter electrical connectors. 6. Install the fuel hoses. 7. Position the fuel hose clamps. 8. Prime the fuel system. Refer to Fuel System Priming. 9. Start the engine. If the engine stalls, repeat the above step. 10. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 4522 Fuel Filter: Service and Repair Fuel Filter Element FUEL FILTER REPLACEMENT REMOVAL PROCEDURE 1. Drain the fuel from the fuel filter. Refer to Water-in-Fuel Draining Procedure. 2. Reposition the fuel hose clamps. 3. Remove the fuel hoses. 4. Disconnect the fuel filter connectors. 5. Unscrew the fuel filter from the fuel filter adapter. 6. Remove the water-in-fuel sensor from the fuel filter. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 4523 1. Install the water-in-fuel sensor to the NEW fuel filter. IMPORTANT: Inspect the fuel heater element housing for contamination. Contamination on the fuel heater element housing may cause leakage at the fuel filter. Coat the fuel filter seal with clean engine oil. 2. Screw on the NEW fuel filter to the fuel filter adapter. 3. Connect the fuel filter connectors. 4. Install the fuel hoses. 5. Position the fuel hose clamps. 6. Prime the fuel system. Refer to Fuel System Priming. 7. Start the engine. If the engine stalls, repeat the above step. 8. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 4524 Fuel Filter: Service and Repair Fuel Filter Life Reset FUEL FILTER LIFE RESET This message will appear when a reset is performed either by using the steering wheel controls or the following manual procedure. For vehicles with steering wheel controls: 1. Reset the fuel filter monitor. 2. Press and hold the select button for five seconds while the "FUEL FILTER LIFE" message is displayed. This message will appear on the DIC for ten seconds. For vehicles without steering wheel controls, do the following: 1. Without pressing the pedals, turn the ignition key to the "ON" position without starting the engine. 2. Wait five seconds. 3. Completely press the brake and the accelerator pedals simultaneously and hold for ten seconds. The system is now reset. 4. Turn the ignition key off. The next time the engine is started, the message will no longer be displayed. Always reset the FUEL FILTER LIFE system after a fuel filter change. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 4525 Fuel Filter: Service and Repair Fuel System Priming FUEL SYSTEM PRIMING IMPORTANT: In order for the DURAMAX diesel engine fuel system to work properly, the fuel lines must be full of fuel and contain no air. If air gets into the fuel lines, it will be necessary to prime the fuel system to eliminate the air before operating the vehicle. Air could have entered to system in one of the following ways: - The vehicle ran out of fuel. - The filter was removed for service or replacement. - The fuel lines were removed or disconnected for servicing. - The fuel filter water drain cock was opened while the engine was running. If one or more of the above occurred, air has entered the fuel system and you will need to prime the system prior to operating the vehicle. 1. Prior to priming the engine, ensure that the following is complete: - There is fuel in the fuel tank. - The fuel filter has been installed and properly tightened. - The fuel lines are properly connected. - The fuel filter is cool to the touch. - Any dirt or debris is removed from the fuel filter head and vent valve. 2. Open the vent valve by turning the screw counterclockwise several full turns. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 4526 3. Operate the priming pump until a small amount of fuel seeps from the vent valve. allow the pump to return upwards between pumps. When fuel is present, the filter is full of fuel and the system should be primed. 4. Close the vent valve. 5. Clean any fuel which accumulated on the fuel filter. 6. Start the engine and allow it to idle for a few minutes. 7. Check the filter for leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications GThe minimum compression in any one cylinder is 2069 kPa (300 psi). There should not be more than 345 kPa (50 psi) difference between a suspect cylinder and the average compression of all 8 cylinders. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 4530 Compression Check: Testing and Inspection Engine Compression Test ^ Tools Required J 26999 Compression Gage - J 26999-20 Compression Gage Adapter - J 43244 Relay Puller Pliers 1. Ensure that the vehicle's batteries are in good condition, and fully charged. 2. Operate the vehicle until the engine is at normal operating temperature. 3. Shut off engine. 4. Disable fuel delivery system, by removing the IGN B relay with J 43244. 5. Disconnect glow plug nut; remove all 8 glow plugs. All 8 glow plugs must be removed from the engine during each cylinder test to obtain valid test results. 6. Prior to taking a compression reading, verify the cranking speed is greater than 140 RPM. If the cranking speed is below 140 RPM, repair the slow cranking speed condition before continuing with the compression test. Refer to Engine Cranks Slowly in Engine Electrical. 7. Install the J 26999-20 in the glow plug hole for the cylinder that is being checked. 8. Notice: Do not add oil to any cylinder during a compression test as extensive engine damage may result. Connect the J 26999 to the J 26999-20. 9. Using the vehicle's starter motor, rotate or crank the engine for 6 compression strokes, puffs, for the cylinder being tested. 10. Observe the J 26999 and note the reading as the compression test is being performed. A normal cylinder reading will be indicated if compression builds up quickly and evenly to the specified level. An abnormal reading will be indicated if compression is low on the first compression stroke, starts increasing on the following compression strokes but does not reach the specified level. 11. Record the compression reading for the cylinder just tested. 12. Disconnect the J 26999 from the J 26999-20 and remove adapter from the glow plug hole. 13. Repeat steps 8 through 13 for all remaining cylinders. All 8 cylinders must be tested to obtain valid test results. Record the readings. 14. The minimum compression in any one cylinder is 2069 kPa (300 psi). There should not be more than 345 kPa (50 psi) difference between a suspect cylinder and the average compression of all 8 cylinders. ^ Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. ^ Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes but does not reach normal. ^ Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Lash ........................................................................................................................................... .................................................. 0.3 mm (0.012 inch) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 4534 Valve Clearance: Adjustments Valve Clearance Adjustment 1. Remove the fan clutch. 2. Remove the upper valve rocker arm covers. 3. Rotate the crankshaft in order to bring the number 1 cylinder to Top Dead Center (TDC) of the compression stroke. The number 1 cylinder is the front cylinder on the right bank. The mark on the crankshaft balancer should be aligned with the mark on the engine. 4. Loosen the valve adjusting screws. 5. Insert a feeler gauge between the tip of the rocker arm and the valve bridge. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 4535 6. Adjust the valve lash to 0.3 mm (0.012 inch). Refer to Valve Clearance Adjustment Specifications to determine which valves can be adjusted when the engine is at TDC. Notice: Refer to Fastener Notice in Service Precautions. 7. Tighten the lock nut. Tighten nut to 22 Nm (16 ft. lbs.). 8. Rotate the crankshaft one revolution in order to bring the number 1 cylinder to TDC of the exhaust stroke. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 4536 9. Loosen the valve adjusting screws. 10. Insert a feeler gage between the tip of the rocker arm and the valve bridge. 11. Adjust the valve clearance to 0.3 mm (0.0112 inch). Refer to Valve Clearance Adjustment Specifications to determine which valves can be adjusted when the engine is at TDC. 12. Tighten the lock nut. Tighten nut to 22 Nm (16 ft. lbs.). 13. Install the upper valve rocker arm covers. 14. Install the fan clutch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4541 Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4542 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SYSTEM DESCRIPTION The accelerator pedal position (APP) system along with the vehicle electronics and components is used to calculate and control the amount of acceleration and deceleration via fuel injector control. This eliminates the need for a mechanical cable attachment from the accelerator pedal to a throttle body. The APP system includes, but is not limited to, the following components : - The accelerator pedal position (APP) sensor assembly - The engine control module (ECM) Accelerator Pedal Position (APP) Sensor The accelerator pedal position (APP) sensor is mounted on the accelerator pedal control assembly. The sensor is made up of 3 individual sensors within one housing. Three separate signal, low reference, and 5-volt reference circuits are used in order to interface the accelerator pedal sensor assembly with the ECM. Each sensor has a unique functionality to determine pedal position. The ECM uses the APP sensor to determine the amount of acceleration or deceleration desired by the person driving the vehicle. The APP sensor 1 voltage should increase as the accelerator pedal is depressed, from below 1.0 volt at 0 pedal travel to above 2 volts at 100 percent pedal travel. APP sensor 2 voltage should decrease from above 4 volts at 0 pedal travel to below 3.0 volts at 100 percent pedal travel. APP sensor 3 voltage should decrease from above 3.8 volts at 0 percent pedal travel to below 3.3 volts at 100 percent pedal travel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4543 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION (APP) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector. 3. Reposition the carpet to access the lower nut. 4. Remove the accelerator pedal nuts. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4544 1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Service Precautions. 2. Install the accelerator pedal nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Connect the APP sensor electrical connector. 4. Reposition the carpet. 5. Install the CPA retainer. 6. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 7. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle and a wide open throttle (WOT). 8. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 9. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Mass Air Flow (MAF) Sensor: Locations Right Side Of The Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4548 Right Side Of Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4549 Intake Air Temperature (IAT)/Mass Airflow (MAF) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4550 Mass Air Flow (MAF) Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector (1). 2. Remove the MAF/IAT sensor TORX(R) screws. 3. Remove the MAF/IAT sensor (1). INSTALLATION PROCEDURE 1. Install the MAF/IAT sensor (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4551 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the MAF/IAT sensor TORX(R) screws. Tighten Tighten the screws to 8 N.m (70 lb in). 3. Connect the MAF/IAT sensor electrical connector (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Intake Air Temperature (IAT) Sensor: Locations Intake Air Temperature (IAT) Sensor is part of the Mass Air Flow (MAF) Sensor and is in the air induction tube. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 4555 Intake Air Temperature (IAT)/Mass Airflow (MAF) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 4556 Intake Air Temperature (IAT) Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector (1). 2. Remove the MAF/IAT sensor TORX(R) screws. 3. Remove the MAF/IAT sensor (1). INSTALLATION PROCEDURE 1. Install the MAF/IAT sensor (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 4557 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the MAF/IAT sensor TORX(R) screws. Tighten Tighten the screws to 8 N.m (70 lb in). 3. Connect the MAF/IAT sensor electrical connector (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations Barometric Pressure Sensor: Locations Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 4561 Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 4562 BARO Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 4563 Barometric Pressure Sensor: Service and Repair BAROMETRIC PRESSURE (BARO) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the barometric pressure (BARO) sensor electrical connector. 2. Push the BARO sensor (1) downward in order to remove it from the bracket. INSTALLATION PROCEDURE 1. Push the BARO sensor (1) upward in order to remove it from the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 4564 2. Connect the BARO sensor electrical connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 05-02-118-002 > Feb > 05 > Steering - 'Service Rear Wheel Steering' Message Body Control Module: Customer Interest Steering - 'Service Rear Wheel Steering' Message Bulletin No.: 05-02-118-002 Date: February 03, 2005 TECHNICAL Subject: DTC C0455, "Service Rear Wheel Steering", System Jumps from 4-Wheel Steer to 2-Wheel Steer (Reprogram BCM) Models: 2003-2005 Chevrolet Silverado, Suburban 2003-2005 GMC Sierra, Yukon XL with 4-Wheel Steer (RPO NYS) Condition Some customers may comment that the system will jump from 4-wheel steer to 2-wheel steer and the DIC displays the message "Service Rear Wheel Steering". Diagnosis will show DTC C0455-Front Steering Position Sensor malfunction. Cause This condition may be caused by a Class2 communication issue. Correction Reprogram the BCM. 2005 Model Year Vehicles: New software calibration, P/N 15248410, was released on TIS version 12 - broadcast to dealers on December 4, 2004. 2003-2004 Model Year Vehicles: New software calibration, P/N 15259330 ('03 Model Year) and P/N 15259331 ('04 04 Model Year), was released on TIS version 1.75 - broadcast to dealers on January 24, 2005. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 05-02-118-002 > Feb > 05 > Steering - 'Service Rear Wheel Steering' Message Body Control Module: All Technical Service Bulletins Steering - 'Service Rear Wheel Steering' Message Bulletin No.: 05-02-118-002 Date: February 03, 2005 TECHNICAL Subject: DTC C0455, "Service Rear Wheel Steering", System Jumps from 4-Wheel Steer to 2-Wheel Steer (Reprogram BCM) Models: 2003-2005 Chevrolet Silverado, Suburban 2003-2005 GMC Sierra, Yukon XL with 4-Wheel Steer (RPO NYS) Condition Some customers may comment that the system will jump from 4-wheel steer to 2-wheel steer and the DIC displays the message "Service Rear Wheel Steering". Diagnosis will show DTC C0455-Front Steering Position Sensor malfunction. Cause This condition may be caused by a Class2 communication issue. Correction Reprogram the BCM. 2005 Model Year Vehicles: New software calibration, P/N 15248410, was released on TIS version 12 - broadcast to dealers on December 4, 2004. 2003-2004 Model Year Vehicles: New software calibration, P/N 15259330 ('03 Model Year) and P/N 15259331 ('04 04 Model Year), was released on TIS version 1.75 - broadcast to dealers on January 24, 2005. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4578 Body Control Module: Locations Body Control Module (BCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4579 Body Control Module (BCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4582 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4583 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4584 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4585 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4586 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4587 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4588 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4589 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4590 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4591 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4592 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4593 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4594 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4595 Body Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4596 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4597 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4598 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4599 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4600 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4601 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4602 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4603 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4604 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4605 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4606 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4607 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4608 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4609 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4610 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4611 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4612 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4613 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4614 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4615 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4616 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4617 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4618 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4619 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4620 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4621 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4622 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4623 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4624 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4625 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4626 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4627 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4628 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4629 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4630 Body Control Module: Connector Views Body Control Module (BCM) - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4631 Body Control Module (BCM) - C2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4632 Body Control Module (BCM) - C2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4633 Body Control Module (BCM) - C2 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4634 Body Control Module (BCM) - C3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4635 Body Control Module (BCM) - C3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4636 Body Control Module (BCM) - C4 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4637 Body Control Module (BCM) - C4 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4638 Body Control Module (BCM) - C5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4639 Body Control Module (BCM) - C6 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4640 Body Control Module (BCM) - C6 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4641 Body Control Module: Electrical Diagrams Door Control Module Diagram 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4642 Door Control Module Diagram 2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4643 Door Control Module Diagram 2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4644 Door Control Module Diagram 3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4645 Door Control Module Diagram 3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 4646 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The body control module (BCM) monitors several inputs in order to arm and disarm the CTD system. The BCM controls the alarm function outputs. When the BCM detects an unauthorized entry (any door opened), the BCM applies ground to the horn, the park lamp and the headlamp relays. The BCM will send messages to the security telltale in the instrument cluster through the Class 2 serial data link. The BCM has the following 8 basic modes for operating the CTD system. The more detailed descriptions are below. - Off state - Idle state - Disarmed state - Ready-to-arm state - Arm initiated state - Arm delay state - Armed state - Alarm state The BCM has the following 6 discrete inputs in order to monitor the CTD system: - Ignition 1 - Driver door latch (door jamb) switch - Passenger door latch (door jamb) switch - Door lock relay - Door key switch - Passenger door unlock relay The BCM applies ground once per second for approximately 2 minutes, or until a valid input to disarm the system is received by the BCM. The Body Control Module (BCM) contains the theft deterrent system logic. The BCM reads the Passlock(TM) data from the Passlock(TM) sensor. If the Passlock(TM) data is correct, the BCM will pass theft. The BCM will then transmit the fuel continue password to the VCM/PCM. During the tamper mode the vehicle may start. The vehicle will then stall. If the BCM receives the wrong Passlock(TM) data, the VTD will immediately go into the tamper mode. The tamper mode will lock-out the vehicle fuel injectors for 10 minutes. The SECURITY indicator will flash while the VTD is in the tamper mode. If the Passlock(TM) sensor sends a correct password to the BCM when the ignition is in the ON position, the BCM will send a fuel enable signal to the VCM/PCM. The VCM/PCM will not disable the fuel due to any BCM message for the remainder of the ignition cycle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION The procedures below are designed to set-up the body control module (BCM) correctly during BCM related service. Before you start, read these procedures carefully and completely. IMPORTANT: The following procedures must be followed: 1. Programming the BCM. 2. Programming Theft Deterrent System Components, if equipped with Passlock System. PROGRAMMING THE BCM IMPORTANT: After the procedure is completed, the personalization settings of the BCM are set to a default setting. Inform the customer that the personalization must be set again. Perform the BCM special function Request BCM Info. for service programming system (SPS), then follow the SPS instructions. Refer to Service Programming System (SPS) in Programming. PROGRAMMING THEFT DETERRENT SYSTEM COMPONENTS IMPORTANT: This procedure has to be performed only for vehicles equipped with Passlock System. Perform the Programming Theft Deterrent System Components in Theft Deterrent after successfully finishing the Setup New BCM procedure. If the Programming Theft Deterrent System Components in the Theft Deterrent procedure is not performed after a BCM replacement, one of the following conditions will occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank or start. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON, with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 4649 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable(s). 2. Remove the knee bolster. 3. Disconnect the brown connector. 4. Disconnect all other connectors (1). 5. Remove the BCM from the sliding bracket. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 4650 1. Slide the BCM onto the bracket. 2. Connect all the connectors (1) except the brown connector. 3. Connect the brown connector. 4. Install the knee bolster. 5. Connect the negative battery cable(s). 6. Reprogram the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. 7. Perform the Passlock Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Brake Pressure Switch > Component Information > Locations Chassis And License Lamp Harnesses Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Right Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4658 Camshaft Position (CMP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Replacement CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the cooling fan pulley. 2. Remove the camshaft position (CMP) sensor bolt. 3. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Lubricate the CMP sensor O-ring with clean engine oil. 2. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the CMP sensor bolt. Tighten Tighten the bolt to 10 N.m (89 lb in). 4. Install the cooling fan pulley. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement > Page 4661 Camshaft Position Sensor: Service and Repair Camshaft Reluctor Replacement Camshaft Reluctor Replacement Removal Procedure Notice: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 1. Remove the engine front cover. 2. While holding the secondary oil pump shaft with a hex driver, remove the oil pump driven gear nut. 3. Remove the oil pump driven gear. 4. Important: DO NOT remove the reluctor from the oil pump drive gear. The reluctor is timed to the gear and once removed the correct timing will be lost. Remove the oil pump drive gear and crankshaft sensor reluctor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement > Page 4662 5. Remove the camshaft reluctor screws. 6. Remove the camshaft reluctor. 7. Clean and Inspect the camshaft reluctor for damage. Replace the reluctor if damage is found. Installation Procedure 1. Position the camshaft reluctor to the camshaft gear. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the camshaft reluctor bolts. Tighten the bolts to 9 Nm (80 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement > Page 4663 3. Important: Do not damage the teeth on the reluctor. Install the oil pump drive gear and reluctor to the crankshaft. 4. Install the oil pump driven gear. 5. While holding the secondary oil pump shaft with a hex driver, install the oil pump driven gear nut. Tighten the nut to 100 Nm (74 ft. lbs.). 6. Install the engine front cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations SEO Harness Routing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Upper Front of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4670 Engine Coolant Temperature (ECT) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4671 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the coolant to a level below the engine coolant temperature (ECT) sensor. 2. Disconnect the ECT sensor electrical connector. 3. Remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4672 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor (1). Tighten Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector. 4. Fill the cooling system, if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Starter Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4676 Right Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4677 Crankshaft Position (CKP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4678 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the right wheelhouse panel. 3. Disconnect the crankshaft position (CKP) sensor electrical connector. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. 6. If necessary, remove the CKP sensor spacer bolts. 7. If necessary, remove the CKP sensor spacer. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4679 1. If necessary, lubricate a NEW CKP spacer O-ring with clean engine oil. 2. If necessary, install the NEW O-ring to the CKP sensor spacer. IMPORTANT: The crankshaft position sensor spacers are machined with different timing positions. However, if the crankshaft position sensor spacer requires replacement, replace with a grade "C" spacer. 3. If necessary, install the CKP sensor spacer. NOTE: Refer to Fastener Notice in Service Precautions. 4. If necessary, install the CKP sensor spacer bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). 5. Lubricate a NEW CKP sensor O-ring with clean engine oil. 6. Install the NEW O-ring to the CKP sensor. 7. Install the CKP sensor. 8. Install the CKP sensor bolt. Tighten Tighten the bolt to 10 N.m (89 lb in). 9. Connect the CKP sensor electrical connector. 10. Install the right wheelhouse panel. 11. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Lower Left Of The I/P Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 4683 Data Link Connector: Description and Operation DATA LINK CONNECTOR (DLC) The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: - Scan tool power battery positive voltage at terminal 16 - Scan tool power ground at terminal 4 - Common signal ground at terminal 5 - Class 2 signal at terminal 2 - High speed GMLAN serial data bus (+) at terminal 6 - High speed GMLAN serial data bus (-) at terminal 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 4684 Data Link Connector: Service and Repair DATA LINK CONNECTOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the bolt from the data link connector. 2. Remove the data link connector from the instrument panel. INSTALLATION PROCEDURE 1. Install the data link connector to the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the data link connector bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 4689 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 4690 Engine Control Module: Technical Service Bulletins Diesel Engine - Damage Due To Power-Up Devices INFORMATION Bulletin No.: 06-06-01-007F Date: March 31, 2010 Subject: Information On Identifying Duramax(TM) Diesel LB7, LLY, LMM, LBZ Overpower Engine Breakdown or Non-Function Due to Aftermarket Power-Up Devices vs. Non Overpower Engine Non-Function of Pistons, Cylinders, Valvetrain Components and/or Turbocharger DTC P003A Set Models: 2001-2010 Chevrolet Silverado 2003-2009 Chevrolet Kodiak 2006-2010 Chevrolet Express 2001-2010 GMC Sierra 2003-2009 GMC TopKick 2006-2010 GMC Savana Equipped With Duramax(TM) Turbocharged Diesel Engine RPOs LB7, LLY, LMM, LBZ Please Refer to GMVIS Supercede: This bulletin is being revised to add text to the end of the Caution statement. Please discard Corporate Bulletin Number 06-06-01-007E (Section 06 - Engine/Propulsion System). Caution Customers should be informed if a hard part failure is observed in the engine, transmission, transfer case and/or other driveline components, it is likely that powertrain components were weakened to the point of premature failure, while subjected to the higher stresses from Aftermarket Power-Up Devices. Failures associated with the installation of Aftermarket Power-Up Devices, which have been verified, are not covered under the terms of the New Vehicle Warranty. In the majority of these cases, the Fixed Operations Manager (FOM) (in Canada, Warranty Manager) should be contacted and the remaining portion of the powertrain portion of the New Vehicle Warranty blocked. GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage. General Motors Position On Aftermarket Power-Up Devices Important General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. Refer to Service Bulletin Number 04-06-04-054A or newer - Warranty Admin. - Non-GM Parts and Accessories (Aftermarket). Important For further information on aftermarket power-up kits, refer to February 2006 Emerging Issues Course Number 10206.02D. In Canada, information on aftermarket power-up kits was covered in the April 2006 TAC TALK program. Aftermarket power-up devices are non-approved by General Motors. These devices are usually piggy-backed in the main engine harness or remain connected to the diagnostic connector to upload the calibration to the ECM. Recent warranty reviews of returned engines show engine breakdown or non-function due to power-up devices that are utilized for increased horsepower and torque. The following information will assist technicians in identifying overpower engine breakdown or non-function due to aftermarket power-up devices vs. non overpower engine breakdown or non-function. Non-GM parts can alter the design of the vehicle. GM dealers need to be aware of the quality of parts being installed on vehicles. If failure occurs as a result of installation of sub-par parts, warranty coverage may be denied. Refer to Service Bulletin Number 04-06-04-054A or newer Warranty Admin. - Non-GM Parts and Accessories (Aftermarket). Installed Power-Up Kit Aftermarket power-up kits have become a very popular add on for performance-minded customers. These devices can add horsepower and torque and can add additional stress to the engine. These aftermarket calibrations take the Duramax(TM) powertrain outside of its design torque and horsepower rating. They do this by altering air/fuel ratios and injector timing, resulting in excessive cylinder pressure and temperature. When these calibrated parameters are altered, it will upset the design balance and can lead to a reduction of engine life expectancy. Generally, in inspection of Duramax(TM) engine failure due to power-up failures, two or more cylinders will be affected. Installed Power-Up Kit - Once installed, the calibration may mask itself with the factory original calibration ID and may remain the same. Refer to Service Bulletin Number 08-06-04-006F or newer - Information on Identifying Non-GM Calibration Usage for LMM Duramax(TM) Diesel Engine. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 4691 - A Tech 2(R) will not positively enable you to identify the use of a power-up device. - Some companies that offer power-up devices claim increases of 150 or more horsepower and 300 or more lb/ft pounds of torque. - A vehicle that is used to the power-up device potential 100% of the time will see earlier engine wear and breakdown. - A vehicle that takes advantage of additional power, but on a less frequent basis, may not see premature engine wear and breakdown until later in the engine's life. - A vehicle not pushed to its limits of the power-up device often may not encounter premature wear and breakdown until after the engine is out of warranty. Duramax(TM) Powertrain Horsepower / Torque Ratings The following horsepower and torque increase over the past years required new internal components to accommodate the increase. - LB7 - 300 hp with 520 ft/lb of torque for model years 2000-2004 - LLY - 310 hp with 605 ft/lb of torque for model years 2004-2008 - LBZ - 360 hp with 650 ft/lb of torque for model year 2006-2008 - LMM - 365 hp with 660 ft/lb of torque for model year 2007-2009 LBZ Improvements To reliably achieve an increase in 50 horsepower with 45 ft/lb torque, the Duramax (TM) diesel had to be revised in many areas. A few of the revisions on the 2006 LBZ were: - New pistons with a revised compression ratio. - Wrist pins that are larger in diameter. - Connecting rods with added material to increase the I section strength. - Engine block and machining changes - Cylinder heads Duramax(TM) Life Expectancy The Duramax(TM) 6.6L V8 Turbo Diesel Engine is sold with a warranty of 100,000 miles/160,000 kilometers. The Duramax(TM) has been tested to survive upwards of 200,000 miles/320,000 kilometers. The Duramax(TM) powertrain is designed for reliability, peak horsepower and torque within its design limits. When a customer installs a power-up device, it drastically reduces the mileage ratings. Important Cylinder Wall Spotting (commonly referred to leopard spots) is from the induction hardening process of the top 1/3 of the cylinder wall. This is normal for the Duramax (TM) Diesel. Identifying Fuel Related Aftermarket Power-Up Devices Aftermarket companies have developed a performance pressure relief fuel valve for Duramax(TM) diesel engines. Refer to above graphic illustration. The performance pressure relief fuel valve attaches to the fuel rail in place of the OEM valve and will not allow any fuel return to the tank, giving 100% of the fuel to be available for additional engine performance. This may cause additional fuel related driveability concerns and may set the following DTCs: - DTC P1093 Fuel Rail Pressure (FRP) Low During Power Enrichment - DTC P0087 Fuel Rail Pressure (FRP) Too Low Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 4692 Aftermarket companies have developed a replacement performance/economy fuel injector nozzle. Refer to above illustration. The performance/economy fuel injector nozzles replace the OEM fuel injector nozzles. The aftermarket companies claim increased horsepower, improved fuel atomization, lower exhaust gas temperatures and increase fuel economy. This may cause additional fuel related driveability concerns and may cause internal engine damage to the pistons and fuel injector nozzles. Identifying Overpower Engine Premature Wear and Breakdown When premature wear and breakdown is encountered due to an aftermarket power-up device, it has some very specific characteristics to the internal engine components. The following list will assist in identifying these characteristics as you tear down the engine. - Pistons will be cracked in the lip area, or a hole in the pistons. - Pistons can also be melted on the lip of the combustion bowl, or the top of the pistons can be melted. - Crosshatch will be polished off the cylinder wall in the major thrust face of cylinder below ring belt travel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 4693 - Piston pin bore will show signs of scoring, the wrist pins will be discolored, and can have oil coking on them. The connecting rod bushing surface will have accelerated wear. The above illustration shows a connecting rod bushing. - Oil coking on the underside of the piston between the wrist pin bosses. - Signs of bearing fretting will also be noticed on the connecting rod and main bearing caps. Refer to the above illustration for fretting of main bearing cap 1 and back side of connection rod bearing 2. - Excessive heat in engine compartment caused by overpower device. Refer to above illustration (1). Non Overpower Engine Premature Wear and Breakdown The following pictures show results of overheat, overspeed, low/no oil pressure or injector breakdown and how they differ from aftermarket power-up device premature wear and breakdown. Engine Overheat Overheat can be caused by a loss of coolant or a general cooling system failure. Some of the indicators of overheat are: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 4694 - Melted pistons. - Head gasket breakdown or non-function. - Warped cylinder heads. - Crankshaft and connecting rod discolored. Engine Overspeed Causes If an engine has been run faster than design capability (redline), and has caused damage as a result, it may be a result of one of the following conditions: - Leaking or failed turbocharger (TC) oil seals. - Oil evident in the intake runners and compressor side of the TC. - Starting fluid use or alternative fuel added to the engine such as ether. Engine Overspeed Results The following are indicators that an overspeed event took place: - Valve train damage. - Pushrods that are bent (4). - Broken valve bridge buttons after cylinder head removal (2). - Rocker arm tip damage (1). - Dry or rusted cylinders from the use of ether, propane or nitrous oxide. - Piston to valve contact. - Cam gear pin shear. Lack of Oil Pressure Lack of lubrication causes rapid bearing wear or bearing to seize. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 4695 Bearing failure. Spun main bearings. Engine Premature Wear and Breakdown Due to Improper Function of Fuel Injector A fuel injector may fracture a piston or melt a piston but the damage will be limited to that cylinder only and all other pistons and cylinder walls are OK. In some cases hydraulic lock will occur on the suspected cylinder with an over-fueling fuel injector. Hydraulic lock on the suspected cylinder will cause a bent connecting rod. This can be verified with piston protrusion measurements. 2007-2010 RPO LMM Only Turbocharger DTC P003A Set General Motors has identified a turbocharger (TC) failure mode involving Power-Up Kits that causes soot leakage and DTC P003A to be set. The Power-Up Kits create an overtemperature condition from the increased exhaust gas temperatures that results in a permanent and excessive turbine housing distortion at the TC case halves. 1. A technician may observe one or more of the following conditions: - DTC P003A being set as Current or in History. - An unusual odor emanating from the TC due to an overtemperature condition. - Soot leaking and accumulating at the V-band clamp that secures the TC case halves together. - Limited or unresponsive travel when Commanding the TC Vane Pos. Ctrl. Solenoid ON and OFF with a scan tool. 2. If DTC P003A is found as Current or in History, OR there is evidence of soot leakage (1) in the area of the V-band clamp (1), then technicians MUST verify if the engine control module (ECM) has a Power-Up Kit aftermarket calibration installed or an aftermarket hardware device has been installed. Refer to Service Bulletin Number 08-06-04-006F or newer for the calibration verification information and procedures. How to Handle a Suspect Engine Failure Due to a Power-Up Device Dealers should not automatically decline warranty assistance on engine failures due to the fact that a power-up device or modification is evident or suspected. The technician must identify that the failure is due to a power-up device by teardown analysis and diagnosis of the engine components. The following steps should be taken if an engine failure occurs and it is suspected that the modification or addition of a power-up device maybe the cause of the engine failure. If unclear of this process or direction feel free to contact your Fixed Operations Manager (in Canada, Warranty Manager) for further support. 1. The technician should use proper engine diagnostics to lead him/her to the failed engine components. The Aftermarket Power-Up Kit Check List should be followed and if it is determined that at least three of the Aftermarket Power-Up Kit Check List items match the engine component failures then it can be decided that the failure is not a warrantable claim. 2. Engine failures that meet at least three criteria of the Aftermarket Power-Up Kit Check List are considered failures that are not manufacturer's defects in workmanship or materials. 3. The dealership should contact the PQC, open a case to review the findings and make the final decision on warranty coverage. The Fixed Operations Manager (in Canada, Warranty Manager) should be notified of the PQC decision. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 4696 4. Denied claims should be documented as follows: 1. The Aftermarket Power-Up Kit Check List completed with the technicians detailed written findings of the diagnosis on the repair order and retained in the repair order file. 2. Photographs of the failed parts should be retained in the repair order file. 5. The customer should be advised that the failure of their engine was not due to a manufacturer's defect in workmanship or materials and therefore the warranty claim is denied on this failure. Aftermarket Power-Up Kit Check List Important Print and use this aftermarket power-up kit check list when performing an engine disassembly investigation of overpower engine breakdown or non-function. Retain a copy of this checklist and photographs of the failed parts in the repair order file. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4697 LF Of The Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 Engine Control Module: Diagrams Engine Control Module (ECM) - C1 Engine Control Module (ECM) - C1 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4700 Engine Control Module (ECM) - C1 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4701 Engine Control Module (ECM) - C1 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4702 Engine Control Module (ECM) - C1 Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4703 Engine Control Module: Diagrams Engine Control Module (ECM) - C2 Engine Control Module (ECM) - C2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4704 Engine Control Module (ECM) - C2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4705 Engine Control Module (ECM) - C2 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4706 Engine Control Module (ECM) - C2 Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4707 Engine Control Module (ECM) - C2 Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4708 Engine Control Module: Diagrams Engine Control Module (ECM) - C3 Engine Control Module (ECM) - C3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4709 Engine Control Module (ECM) - C3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4710 Engine Control Module (ECM) - C3 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4711 Engine Control Module (ECM) - C3 Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Passlock Function Engine Control Module: Description and Operation Passlock Function VEHICLE/POWERTRAIN CONTROL MODULE The VCM/PCM communicates with the BCM over the Class 2 serial data line. When the BCM determines a no start condition, it sends a Class 2 serial data password to the VCM/PCM in order to disable the fuel injection system. If the BCM receives the expected voltage from the Passlock(TM) sensor, the BCM sends a class 2 serial data password to the VCM/PCM in order to enable the fuel injection system. The VCM/PCM then allows the vehicle to start correctly. If the Class 2 serial data password from the BCM to the VCM/PCM is not within the Vehicle Security Status Message, the fuel injectors will shut OFF during a start attempt. The SECURITY telltale will be illuminated for 10 minutes. If the VCM/PCM does not receive the same password from the BCM as the last learned one, the vehicle will start and then stalls due to the Fuel Lockout. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Passlock Function > Page 4714 Engine Control Module: Description and Operation Engine Control Module (ECM) ENGINE CONTROL MODULE (ECM) DESCRIPTION The engine control module (ECM) processes the various input information. The ECM sends the necessary electrical responses to control fuel delivery. The input information has an interrelation to more than one output. One failed input can affect more than one systems operation. Diagnostic System Check - Computers and Control Systems The Diagnostic System Check Computers and Control Systems is an organized approach to identify a problem caused by an electronic engine control system malfunction. This diagnostic check must be the starting point for any driveability complaint diagnosis. The diagnostic directs the technician to the next logical step in diagnosing the complaint. Use the Engine Scan Tool Data Definitions list for a comparison after fulfilling the following items: Complete the Diagnostic System Check-Computers and Control Systems. - Confirm that the on-board diagnostics are functioning properly. - Confirm there are no diagnostic trouble codes. The Engine Scan Tool Definitions are an average of display values recorded from normal operating vehicles. The definitions intend to represent what a normal functioning system should display. IMPORTANT: Do not use a scan tool that displays faulty data. Report the problem to the manufacturer. Using a malfunctioning scan tool can result in misdiagnosis and unnecessary parts replacement. Use only the parameters listed in the Engine Scan Tool Data Definitions for diagnosis. When a scan tool reads other parameters, General Motors recommends not using the values for use in diagnosis. For more description on the values and the use of the scan tool to diagnose the ECM inputs, refer to the applicable diagnostic file. When all the values are within the range illustrated in the Engine Scan Tool Data Definitions, refer to Symptoms - Computers and Control Systems. Control Module Communications The control module system has a computer, the engine control module (ECM), to control fuel delivery, timing, and some emission control systems. The control module system monitors a number of engine and vehicle functions and controls the following operations through the fuel injection control module (FICM): Fuel rail pressure - Fuel injector - Fuel injector pulse width The diesel ECM, located in the engine compartment, is the control center of the control module system. The engine control module used on the electronic fuel injected 6.6L diesel is referred to as a ECM. The ECM constantly looks at the information from various sensors, and controls the systems that affect vehicle performance. The ECM performs the diagnostic function of the system. The ECM can recognize operational problems, alert the driver through the MIL. Service Engine Soon, and store one or more diagnostic trouble codes (DTCs) which identify the problem areas to aid the technician in making repairs. See the specific diagnosis procedure for more information. Malfunction Indicator Lamp (MIL) Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Passlock Function > Page 4715 The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Aftermarket (Add-On) Electrical And Vacuum Equipment Any equipment installed on a vehicle after leaving the factory that connects to the electrical or vacuum systems of the vehicle defines aftermarket (Add-On) electrical and vacuum equipment. The vehicle design makes no allowances for this type of equipment. NOTE: Do not attach add-on vacuum operated equipment to this vehicle. The use of add-on vacuum equipment may result in damage to vehicle components or systems. - Connect any add-on electrically operated equipment to the vehicle's electrical system at the battery (power and ground) in order to prevent damage to the vehicle. The add-on electrical equipment, even when installed to these strict guidelines, may still cause the powertrain system to malfunction. This may also include any equipment which is not connected to the electrical system of the vehicle such as portable telephones and radios. Therefore, the first step in diagnosing any powertrain problem is to eliminate all of the aftermarket electrical equipment from the vehicle. After this is done, if the problem still exists, diagnose the problem in the normal manner. Computers and Control Systems Information The driveability and emissions information describes the function and operation of the control module. The emphasis is placed on the diagnosis and repair of problems related to the system. Engine Components, Wiring Diagrams, and Diagnostic Trouble Code (DTC) tables: The Component Locations - The Wiring Diagrams - The Control Module Terminal End View and Terminal Definitions - The Diagnostic System Check - Computers and Control Systems - The Diagnostic Trouble Code (DTC) tables The Component System includes the following items: The component and circuit description - The On-vehicle service for each subsystem - The Functional checks with the diagnostic tables - How To Use Electrical Systems Diagnostic Information The DTCs also contain the diagnostic support information containing the circuit or the system information, and helpful diagnostic information. Wiring Harness Service The control module harness electrically connects the control module to the various solenoids, switches, and sensors in the vehicle engine compartment and passenger compartment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Passlock Function > Page 4716 Replace the wire harnesses with the proper part number replacement. When splicing signal wires into a harness, use the wiring that has high temperature insulation. Consider the low amperage and voltage levels utilized in the powertrain control systems. Make the best possible bond at all splices. Use rosin-core solder in these areas. Molded-on connectors require complete replacement of the connector. Splice a new connector into the harness. Replacement connectors and terminals are listed in Group 8.965 in the Standard Parts Catalog. Connectors and Terminals In order to prevent shorting between opposite terminals, use care when probing a connector and when replacing terminals. Damage to the components could result. Always use jumper wires between connectors for circuit checking. Never probe through the Weather-Pack seals. The J 35616-B Connector Test Adapter Kit , or the equivalent, contains an assortment of flexible connectors used in order to probe the terminals during the diagnosis. The fuse remover and the BT-8616 Test Tool, or the equivalent, is used for removing a fuse and to adapt the fuse holder to a meter for diagnosis. Open circuits are often difficult to locate by sight because oxidation or terminal misalignment are hidden by the connectors. Merely wiggling a connector on a sensor or in the wiring harness may temporarily correct the open circuit. Oxidized or loose connections may cause intermittent problems. Be certain the type of connector and terminal before making any connector or terminal repair. Weather-Pack and Com-Pack III terminals look similar, but are serviced differently. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Passlock Function > Page 4717 Engine Control Module: Description and Operation Turbocharger ENGINE CONTROL MODULE (ECM) The ECM controls all turbocharger control functions. The ECM monitors information from various sensor inputs that include the following: - The accelerator pedal position (APP) sensor - The engine coolant temperature (ECT) sensor - The mass airflow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The boost pressure sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 4718 Engine Control Module: Service and Repair ENGINE CONTROL MODULE (ECM) REPLACEMENT Service of the engine control module (ECM) should consist of either replacement of the ECM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the ECM to be replaced, the replacement ECM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty ECM and install the new service ECM. REMOVAL PROCEDURE IMPORTANT: - To prevent internal ECM damage, the ignition switch must be OFF when disconnecting or connecting power to the ECM. - Remove any debris from the ECM connector surfaces before servicing the ECM. Inspect the ECM module connector gaskets when diagnosing or replacing the ECM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the ECM. - The replacement ECM must programmed. - It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100%. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5000km (3,000 mi) from the last engine oil change. 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 2. Disconnect the negative battery cable. 3. Disconnect the ECM electrical connectors (2). 4. Release the ECM cover retaining tabs. 5. Remove the ECM cover from the bracket. 6. Remove the ECM cover. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 4719 1. Install the ECM. IMPORTANT: The cover must be fully installed prior to the electrical connections being made to ensure the ECM is fully seated in the bracket. 2. Install the ECM cover to the bracket. 3. Engage the ECM cover retaining tabs. 4. Connect the ECM electrical connectors (2). 5. Connect the negative battery cable. 6. If a NEW ECM was installed, program the ECM. Refer to Service Programming System (SPS) in Programming. See: Testing and Inspection/Programming and Relearning 7. Perform the turbocharger learn procedure. Refer to Turbocharger Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Injector Control Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel Injector Control Module: > 09-06-04-034 > Aug > 09 > Fuel System - Reduced Engine Power, MIL (Various Codes) Fuel Injector Control Module: Customer Interest Fuel System - Reduced Engine Power, MIL (Various Codes) TECHNICAL Bulletin No.: 09-06-04-034 Date: August 17, 2009 Subject: Malfunction Indicator Lamp (MIL) Illuminated, Fuel Injector Driver Circuit DTCs P0201, P0202, P0203, P0204, P0205, P0206, P0207, P0208 and Cylinder Bank Shut Down DTCs P2146 or P2149, Reduced Engine Power (Repair Fuel Injector Control Module (FICM) Harness Chafed Wires) Models: 2001-2004 Chevrolet Kodiak C4500/C5500 Series, Silverado Models 2001-2004 GMC Sierra Models, TopKick C4500/C5500 Series Equipped with Duramax(TM) Diesel Engine RPO LB7 2004-2005 Chevrolet Kodiak, Silverado Models 2004-2005 GMC Sierra Models, TopKick Equipped with Duramax Diesel Engine RPO LLY Please Refer to GMVIS Condition Some customers may comment that the malfunction indicator lamp (MIL) is illuminated or intermittent and there is a significant reduction in engine power (limp home mode). The scan tool may display one or more Injector Driver Circuit DTCs P0201, P0202, P0203, P0204, P0205, P0206, P0207 or P0208 and/or Cylinder Bank Shut Down DTCs P2146 or P2149 set as Current or in History. Cause This condition may be caused by the fuel injector control module (FICM) wiring harness protective conduit rubbing against the back of the alternator, the alternator bracket or the FICM harness retaining bracket. This may result in the conduit rubbing through, exposing the wires inside and chafing of the wire insulation then occurs. Correction 1. Turn ON the ignition, with the engine OFF. 2. Observe the DTC information with the scan tool. 3. If any of the above DTCs are set, then proceed to inspect the FICM wiring harness at the locations outlined in the following steps. 4. Turn OFF the ignition and all accessories and allow the control modules to power down. Note For Silverado and Sierra models only perform Step 5. 5. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. Important DO NOT break off the tab on the electrical connectors. 6. Disconnect the FICM electrical connectors (2) from the FICM (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Injector Control Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel Injector Control Module: > 09-06-04-034 > Aug > 09 > Fuel System - Reduced Engine Power, MIL (Various Codes) > Page 4728 7. Carefully bend up and backwards the FICM wiring harness electrical connectors (1) away from the FICM (4). Note Some of these chafes are very small, possibly the size of a pen tip, but could still cause injector circuit concerns. 8. Inspect the wiring harness for chafing (3) that may result from rubbing at the back of the alternator (2), the alternator bracket or at the FICM harness retaining bracket. If necessary, peel the tape from the area and look for ANY chafes into the wires. ^ If chafing is observed and the conductive portion of the wire IS NOT damaged, apply electrical tape around the wire. ^ If chafing is observed and the conductive portion of the wire IS damaged, then refer to Splicing Copper Wire Using Splice Sleeves in Wiring Repairs in SI. ^ If chafing IS NOT OBSERVED, then refer to the appropriate DTC Diagnostic procedures in SI. 9. Connect the electrical connectors to the FICM. 10. Insulate the harness with suitable material such as conduit or heater hose to prevent a reoccurrence. Note For Silverado and Sierra models only perform Step 11. 11. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 12. Clear the DTCs with a scan tool. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Injector Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector Control Module: > 09-06-04-034 > Aug > 09 > Fuel System - Reduced Engine Power, MIL (Various Codes) Fuel Injector Control Module: All Technical Service Bulletins Fuel System - Reduced Engine Power, MIL (Various Codes) TECHNICAL Bulletin No.: 09-06-04-034 Date: August 17, 2009 Subject: Malfunction Indicator Lamp (MIL) Illuminated, Fuel Injector Driver Circuit DTCs P0201, P0202, P0203, P0204, P0205, P0206, P0207, P0208 and Cylinder Bank Shut Down DTCs P2146 or P2149, Reduced Engine Power (Repair Fuel Injector Control Module (FICM) Harness Chafed Wires) Models: 2001-2004 Chevrolet Kodiak C4500/C5500 Series, Silverado Models 2001-2004 GMC Sierra Models, TopKick C4500/C5500 Series Equipped with Duramax(TM) Diesel Engine RPO LB7 2004-2005 Chevrolet Kodiak, Silverado Models 2004-2005 GMC Sierra Models, TopKick Equipped with Duramax Diesel Engine RPO LLY Please Refer to GMVIS Condition Some customers may comment that the malfunction indicator lamp (MIL) is illuminated or intermittent and there is a significant reduction in engine power (limp home mode). The scan tool may display one or more Injector Driver Circuit DTCs P0201, P0202, P0203, P0204, P0205, P0206, P0207 or P0208 and/or Cylinder Bank Shut Down DTCs P2146 or P2149 set as Current or in History. Cause This condition may be caused by the fuel injector control module (FICM) wiring harness protective conduit rubbing against the back of the alternator, the alternator bracket or the FICM harness retaining bracket. This may result in the conduit rubbing through, exposing the wires inside and chafing of the wire insulation then occurs. Correction 1. Turn ON the ignition, with the engine OFF. 2. Observe the DTC information with the scan tool. 3. If any of the above DTCs are set, then proceed to inspect the FICM wiring harness at the locations outlined in the following steps. 4. Turn OFF the ignition and all accessories and allow the control modules to power down. Note For Silverado and Sierra models only perform Step 5. 5. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. Important DO NOT break off the tab on the electrical connectors. 6. Disconnect the FICM electrical connectors (2) from the FICM (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Injector Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector Control Module: > 09-06-04-034 > Aug > 09 > Fuel System - Reduced Engine Power, MIL (Various Codes) > Page 4734 7. Carefully bend up and backwards the FICM wiring harness electrical connectors (1) away from the FICM (4). Note Some of these chafes are very small, possibly the size of a pen tip, but could still cause injector circuit concerns. 8. Inspect the wiring harness for chafing (3) that may result from rubbing at the back of the alternator (2), the alternator bracket or at the FICM harness retaining bracket. If necessary, peel the tape from the area and look for ANY chafes into the wires. ^ If chafing is observed and the conductive portion of the wire IS NOT damaged, apply electrical tape around the wire. ^ If chafing is observed and the conductive portion of the wire IS damaged, then refer to Splicing Copper Wire Using Splice Sleeves in Wiring Repairs in SI. ^ If chafing IS NOT OBSERVED, then refer to the appropriate DTC Diagnostic procedures in SI. 9. Connect the electrical connectors to the FICM. 10. Insulate the harness with suitable material such as conduit or heater hose to prevent a reoccurrence. Note For Silverado and Sierra models only perform Step 11. 11. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 12. Clear the DTCs with a scan tool. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Injector Control Module > Component Information > Technical Service Bulletins > Page 4735 Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Injector Control Module > Component Information > Diagrams > Fuel Injection Control Module - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Injector Control Module > Component Information > Diagrams > Fuel Injection Control Module - C1 > Page 4738 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Injector Control Module > Component Information > Diagrams > Page 4739 Fuel Injector Control Module: Service and Repair FUEL INJECTION CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the fuel fill cap in order to relieve the fuel pressure. 3. Cut the tie strap attaching the harness to the bracket. 4. Disconnect the fuel injection control module (FICM) electrical connectors. Pull the retainers out until the connectors disengage. 5. Remove and discard the fuel line eyebolts. 6. Remove and discard the fuel line eyebolt washers from the banjo fittings. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Injector Control Module > Component Information > Diagrams > Page 4740 7. Remove the FICM bolts. 8. Remove the FICM with insulators. 9. If necessary, remove the oil level indicator tube bracket bolt from the FICM bracket. 10. If necessary, remove the fuel line and engine harness clips from the FICM bracket. 11. If necessary, remove the FICM bracket bolts. 12. If necessary, remove the FICM bracket. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Injector Control Module > Component Information > Diagrams > Page 4741 1. If necessary, install the FICM bracket. 2. If necessary, install the FICM bracket bolts. 3. If necessary, install the fuel line and engine harness clips to the FICM bracket. NOTE: Refer to Fastener Notice in Service Precautions. 4. If necessary, install the oil level indicator tube bracket bolt to the FICM bracket. Tighten Tighten the bolt to 21 N.m (15 lb ft). IMPORTANT: Ensure that the insulators do not get knocked off when installing the FICM to the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Injector Control Module > Component Information > Diagrams > Page 4742 5. Install the FICM with insulators. 6. Install the FICM bolts. Tighten Tighten the bolt to 20 N.m (14 lb ft). 7. Lubricate the NEW eyebolt washers with diesel fuel prior to installing. 8. Install the NEW eyebolt washers to the banjo fittings. 9. Install the NEW fuel line eyebolts. Tighten Tighten the bolt to 34 N.m (25 lb ft). 10. Connect the FICM electrical connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Injector Control Module > Component Information > Diagrams > Page 4743 Slide the retainers in to engage the connectors. 11. Install a NEW tie strap attaching the harness to the bracket. 12. Connect the negative battery cable. 13. Install the fuel fill cap. 14. Prime the fuel system. Refer to Fuel System Priming. 15. Start the engine. If the engine stalls, repeat the above step. 16. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Fuel Tank - Primary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 4747 Fuel Tank - Secondary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 4748 Fuel Level Sensor: Diagrams Fuel Level Sensor - Primary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 4749 Fuel Level Sensor - Secondary W/Dual Tanks Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 4750 Fuel Level Sensor - Primary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 4751 Fuel Level Sensor - Secondary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 4752 Fuel Level Sensor: Description and Operation FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The engine control module (ECM) sends the fuel level information via the class 2 circuit to the instrument panel cluster (IPC). This information is used for the instrument panel (I/P) fuel gage and the low fuel warning indicator, if applicable. The ECM also monitors the fuel level input for various diagnostics. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 4753 Fuel Level Sensor: Service and Repair FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel level sensor electrical connector (1). 3. Remove the sensor retaining clip (3). 4. Squeeze the locking tangs (2) and remove the fuel level sensor. INSTALLATION PROCEDURE 1. Install the fuel level sensor. 2. Install the sensor retaining clip (3). 3. Connect the sensor electrical connector (1). 4. Install the sending unit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Pressure Sensor > Component Information > Locations Fuel Pressure Sensor: Locations Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Pressure Sensor > Component Information > Locations > Page 4757 Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Pressure Sensor > Component Information > Locations > Page 4758 Fuel Pressure Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Pressure Sensor > Component Information > Locations > Page 4759 Fuel Pressure Sensor: Service and Repair FUEL RAIL PRESSURE (FRP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet duct. 2. Remove the exhaust gas recirculation (EGR) cooler tube. 3. Disconnect the fuel rail pressure sensor electrical connector. 4. Prior to removal, clean the fuel pressure sensor and surrounding area thoroughly with solvent, such as GM P/N 12377981 (Canadian P/N 10953463) or equivalent. 5. Using compressed air, thoroughly blow dry the sensor and surrounding area. 6. Remove the fuel pressure sensor (1). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Pressure Sensor > Component Information > Locations > Page 4760 1. Install the fuel pressure sensor (1). Tighten Tighten the sensor to 70 N.m (52 lb ft). 2. Connect the fuel rail pressure sensor electrical connector. 3. Install the EGR cooler tube. 4. Install the air cleaner outlet duct. 5. Prime the fuel system. Refer to Fuel System Priming. 6. Start the engine. If the engine stalls, repeat the above step. 7. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Locations > Lower Left of the I/P Lower Left Of The I/P Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Locations > Lower Left of the I/P > Page 4766 Splice Pack - SP205 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Locations > Lower Left of the I/P > Page 4767 Splice Pack - SP207 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4770 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4771 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4772 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4773 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4774 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4775 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4776 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4777 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4778 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4779 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4780 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4781 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4782 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4783 Information Bus: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4784 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4785 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4786 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4787 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4788 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4789 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4790 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4791 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4792 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4793 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4794 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4795 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4796 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4797 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4798 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4799 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4800 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4801 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4802 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4803 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4804 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4805 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4806 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4807 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4808 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4809 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4810 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4811 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4812 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4813 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4814 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4815 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4816 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4817 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4818 Data Link Connector (DLC) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4819 Information Bus: Electrical Diagrams Data Link Connector (DLC) Diagram 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4820 Data Link Connector (DLC) Diagram 2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4821 Data Link Connector (DLC) Diagram 2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4822 Data Link Connector (DLC) Diagram 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4823 Data Link Connector (DLC) Diagram 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4824 Data Link Connector (DLC) Diagram 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 4825 Information Bus: Description and Operation DATA LINK COMMUNICATIONS DESCRIPTION AND OPERATION CIRCUIT DESCRIPTION The serial data communication among the control modules is performed through multiple serial data communication links. The class 2 serial data line is always present. The high speed GMLAN or controller area network (CAN) may be present for different vehicle options. The data link connector (DLC) allows a scan tool to communicate with the modules on class 2 or high speed GMLAN serial data lines. In order for the scan tool to communicate with the modules on high speed GMLAN link, a CANdi module is needed. The CANdi module behaves as an interface between the scan tool and the high speed GMLAN data link. The CAN is used for functional communication only, among the modules connected to it. DATA LINK CONNECTOR (DLC) The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: Scan tool power battery positive voltage at terminal 16 - Scan tool power ground at terminal 4 - Common signal ground at terminal 5 - Class 2 signal at terminal 2 - High speed GMLAN serial data bus (+) at terminal 6 - High speed GMLAN serial data bus (-) at terminal 14 CLASS 2 SERIAL DATA LINE lass 2 serial data is transmitted on a single wire at an average of 10.4 kbps. This value is an average, class 2 uses a variable pulse width modulation to carry data and depending on the message it may operate faster or slower. The bus will float at a nominal 7.0 volts during normal operation. Each module can pull this lower during the transmission. The bus is not at battery positive voltage or ground potential during normal operation. When the ignition switch is in RUN, each module communicating on the class 2 serial data line sends a state of health (SOH) message every 2 seconds to ensure that the module is operating properly. When a module stops communicating on the class 2 serial data line, for example if the module loses power or ground, the SOH message it normally sends on the data line every 2 seconds disappears. Other modules on the class 2 serial data line, which expect to receive that SOH message, detect its absence; those modules in turn set an internal DTC associated with the loss of SOH of the non-communicating module. The DTC is unique to the module which is not communicating, for example, when the inflatable restraint sensing and diagnostic module (SDM) SOH message disappears, several modules set DTC U1088. Note that a loss of serial data DTC does not normally represent a failure of the module that set it. The class 2 serial data line on this vehicle is a star configuration. The powertrain control module (PCM) has an additional class 2 serial data circuit to body control module (BCM). If one of the class 2 serial data circuits to the PCM opens, communication will not be interrupted. The following modules communicate on the class 2 serial data line: The audio amplifier (early production)- Refer to Radio/Audio System Description and Operation in Radio, Stereo and Compact Disc for more information. - The body control module (BCM) - The digital radio receiver (DRR) - The driver door module (DDM) - The driver seat module (DSM) - The electronic brake control module (EBCM) - The front passenger door control module (FPDM) - The HVAC control module - The hybrid control module (HCM), for PHT - The inflatable restraint sensing and diagnostic module (SDM) - The instrument panel cluster (IPC) - The powertrain control module (PCM) - The radio - The rear seat audio (RSA) controller - The rear seat entertainment (RSE) assembly, w/U42 - The rear wheel steering control module (RWSCM) - The remote playback device. CD player (CDX), w/U1S - The transfer case shift control module (TCSCM), w/4WD - The transmission control module (TCM), w/Allison Transmission - The vehicle communication interface module (VCIM), w/UE1 The class 2 serial data line allows a scan tool to communicate with these modules for testing purposes, checking for DTCs, and to activate/enable/disable functions. These class 2 serial data circuits are bussed together via two splice packs: SP205.Located behind the I/P near the headlamp switch connector. - SP207.Located in the I/P harness. Refer to Data Link Communications Component Views. CONTROLLER AREA NETWORK (CAN) SERIAL DATA LINE W/6.6L ENGINE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 4826 The controller area network (CAN) serial data line does not communicate with the scan tool via the DLC. CAN serial data information is interpreted by the modules that are on the class 2 also, and transmitted to the scan tool. The following modules communicate on the CAN serial data line: The engine control module (ECM) - The transmission control module (TCM) - The fuel injection control module (FICM) - The glow plug control module, w/LLY The CAN serial data line, based on J1939 SAE standard, is high speed serial data bus used to communicate information among the modules. Typical data-transmission speeds must be high enough to ensure that the required real-time response is maintained. The addressing scheme employed with CAN assigns a label to every message, with each message receiving a unique identifier. The identifier classifies the content of the message. Each module processes only those messages whose identifiers are stored in the module's acceptance list. This is CAN's form of message filtering. The identifier labels both the data content and the priority of the message being sent. Each module can begin transmitting its most important data as soon as the bus is unoccupied. When more than one module starts to transmit simultaneously, the message with the highest priority is assigned first access. A module responds to failure to gain access by automatically switching to receive mode, the module then repeats the transmission attempt as soon as the bus is free again. HIGH SPEED GMLAN SERIAL DATA LINE (PHT) The data link connector (DLC) allows a scan tool to communicate with the high speed GMLAN serial data circuit through the CANdi module. The serial data is transmitted on two twisted wires that allow speed up to 500 Kbps. The twisted pair is terminated with two 120 ohms resistors, one is internal to the ECM and the other is internal to the ESCM. The resistors are used to reduce noise on the high speed GMLAN bus during normal vehicle operation. The high speed GMLAN is a differential bus. The high speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level. The idle level which is approximately 2.5 volts is considered a recessive transmitted data and is interpreted as a logic 1. Driving the lines to their extremes adds 1 volt to high speed GMLAN serial data bus (+) and subtracts 1 volt from high speed GMLAN serial data bus (-) wire. This dominant state is interpreted as a logic 0. GMLAN network management supports selective start up and is based on virtual networks. A virtual network is a collection of signals started in response to a vehicle event. The starting of a virtual network signifies that a particular aspect of the vehicles's functionality has been requested. A virtual network is supported by virtual devices which represents a collection of signals owned by a single physical device. So, any physical device can have one or more virtual devices. The signal supervision is the process of determining whether an expected signal is being received or not. Failsofting is the ability to substitute a signal with a default value or a default algorithm, in the absence of a valid signal. Some messages are also interpreted as a 'heartbeat' of a virtual device. If such a signal is lost, the application will set a no communication code against the respective virtual device. This code is mapped as a code against the physical device. Note that a loss of serial data DTC does not normally represent a failure of the module that set it. The powertrain control module (PCM) and hybrid control module (HCM) are functionally communicating on both class 2 and high speed GMLAN data links. However the diagnostic communication of the above modules with the scan tool is performed on class 2 data link only. All diagnostic trouble codes (DTCs) set by the high speed GMLAN modules, including HCM, are reported by the PCM on class 2. Data displaying, output controls and programming of the control modules connected to high speed GMLAN only, is performed through high speed GMLAN link. The GMLAN serial data communications circuit is in a linear topology. The following modules are connected to the link, in order from DLC to the end of the linear configuration: The energy storage control module (ESCM) - The starter/generator control module (SGCM) - The electro-hydraulic power steering (EHPS) - The hybrid control module (HCM) - The powertrain control module (PCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT - DATA LINK COMMUNICATIONS Begin the diagnosis of the Data Link Communications by performing the Diagnostic System Check for the system in which the customer concern is apparent. The Diagnostic System Check will direct you to the correct procedure within the Data Link Communications section when a communication malfunction is present. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4829 Information Bus: Symptom Related Diagnostic Procedures A Symptoms - Data Link Communications SYMPTOMS - DATA LINK COMMUNICATIONS IMPORTANT: The following steps must be completed before using the symptom tables. 1. Perform the applicable diagnostic system check before using the symptom tables in order to verify that there are no DTCs set. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Data Link Communications Description and Operation. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the systems. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Scan Tool Does Not Power Up - Scan Tool Does Not Communicate with Class 2 Device - Scan Tool Does Not Communicate with High Speed GMLAN Device Scan Tool Does Not Communicate With Class 2 Device SCAN TOOL DOES NOT COMMUNICATE WITH CLASS 2 DEVICE CIRCUIT DESCRIPTION Modules connected to the class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. Connecting a scan tool to the data link connector (DLC) allows communication with the modules for diagnostic purposes. DIAGNOSTIC AIDS The engine will not start when there is a total loss of class 2 serial data communication while the ignition is OFF. The following conditions will cause a total loss of class 2 serial data communication: A class 2 serial data circuit shorted to ground. - A class 2 serial data circuit shorted to voltage. - An internal condition within a module or connector on the class 2 serial data circuit, that causes a short to voltage or ground to the class 2 serial data circuit. TEST DESCRIPTION Steps 1 - 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4830 Steps 3 - 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4831 Steps 7 - 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4832 Steps 11 - 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4833 Steps 15 - 17 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4834 Steps 18 - 20 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4835 Steps 21 - 23 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4836 Steps 24 - 29 The numbers below refer to the step numbers on the diagnostic table. 2. A partial malfunction in the class 2 serial data circuit uses a different procedure from a total malfunction of the class 2 serial data circuit. The following modules communicate on the class 2 serial data circuit: The audio amplifier (AMP). early production.Refer to Radio/Audio System Description and Operation in Radio, Stereo and Compact Disc for more information. - The body control module (BCM) - The CD changer (CDX) - The driver door module (DDM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4837 - The digital radio receiver (DRR) - The driver seat module (DSM) - The electronic brake control module (EBCM) - The front passenger door module (FPDM) - HVAC Control Module - The hybrid control module (HCM), for PHT - The instrument panel cluster (IPC) - The powertrain control module (PCM) - Radio - The rear seat audio (RSA) controller - The rear seat entertainment (RSE) assembly - The rear wheel steering control module (RWSCM) - The inflatable restraint sensing and diagnostic module (SDM) - The transmission control module (TCM) - The transfer case shift control module (TCSCM) - The vehicle communication interface module (VCIM) 3. The following DTCs may be retrieved with a history status, but are not the cause of the present condition. - U1300 - U1301 - U1305 6. A state of health DTC with a history status may be present along with a U1000 or U1255 code having a current status. This indicates that the malfunction occurred when the ignition was ON. 7. Data link connector terminals 2 and 5 provide the connection to the class 2 serial data circuit and the signal ground circuit respectively. 10. A poor connection at DLC terminal of the splice pack SP205 would cause this condition but will not set a DTC. 11. An open or a short in the class 2 serial data circuit between the DLC and splice pack SP205 will prevent the scan tool from communicating with any module. This condition will not set a DTC. 13. This test isolates the BCM class 2 serial data circuits. 16. The BCM detects that the ignition is ON and sends the appropriate power mode message to the other modules. Therefore, the BCM must remain connected to the DLC for any other module to communicate with the scan tool. This test isolates the splice pack SP207 serial data circuits. 21. This test isolates the rest of the splice pack SP205 serial data circuits. 25. If there are no current DTCs that begin with a "U", the communication malfunction has been repaired. 26. The communication malfunction may have prevented diagnosis of the customer complaint. Scan Tool Does Not Communicate With High Speed GMLAN Device SCAN TOOL DOES NOT COMMUNICATE WITH HIGH SPEED GMLAN DEVICE CIRCUIT DESCRIPTION Modules connected to the high speed GMLAN serial data circuits monitor for serial data communications on the high speed GMLAN network during normal vehicle operation. Operating information and commands are exchanged among the modules. The scan tool communicates with the following modules via the high speed GMLAN: The energy storage control module (ESCM) - The starter/generator control module (SGCM) - The electro-hydraulic power steering (EHPS) module DIAGNOSTIC AIDS IMPORTANT: The scan tool communication with the modules connected only to high speed GMLAN data link requires the use of the CANdi module. Due to configuration of this vehicle, they may be communication DTCs set against modules that are able to communicate with the scan tool. The following conditions may cause a total loss of high speed GMLAN data communication: A short between high speed GMLAN (+) and high speed GMLAN (-) circuits - Any of the high speed GMLAN serial data circuits shorted to ground or voltage - A module internal malfunction that causes a short to voltage or ground on the high speed GMLAN circuits TEST Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4838 Steps 1 - 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4839 Step 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4840 Steps 6 - 12 Scan Tool Does Not Power Up SCAN TOOL DOES NOT POWER UP CIRCUIT DESCRIPTION The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: Scan tool power battery positive voltage at terminal 16 - Scan tool power ground at terminal 4 - Common signal ground at terminal 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4841 The scan tool will power up with the ignition OFF. Some modules however, will not communicate unless the ignition is ON and the power mode master (PMM) module sends the appropriate power mode message. TEST DESCRIPTION Steps 1 - 4 The number below refers to the step number on the diagnostic table. 4. If the battery positive voltage and ground circuits of the DLC are functioning properly. The malfunction must be due to the scan tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4842 Information Bus: Scan Tool Testing and Procedures DATA LINK REFERENCES IMPORTANT: There are modules in this vehicle that communicate on a controller area network (CAN) serial data link. This CAN serial data link is not connected to the data link connector (DLC), and the scan tool cannot communicate on this link. Communication DTCs for this CAN Serial data link may be set by the module acting as an interface to the other serial data links. Refer to Data Link Connector (DLC) Schematics for CAN serial data circuits. The following DTCs may be set when the interface module detects a loss of communication with a module on the CAN serial data link. Diagnose these DTCs as directed in the DTC Table: CAN Serial Data - Powertrain Control Module (PCM) and Transmission Control Module (TCM) DTC U0100, U0101, U0105 or U0106-Refer to DTC U0100-U0299 (Diesel Engine)DTC U0100-U0299 (HP2) See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures - DTC U1800, U2105 or U2106-Refer to DTC U1800, U2105, U2106, or U2108 See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U1800 See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U2105 See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U2106 See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U2108 For any other U codes or communication problems, refer to the table below for the correct procedure. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4843 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4844 This table identifies which serial data link that a particular module uses for in-vehicle data transmission. Some modules may use more than one data link to communicate. This table is used to assist in correcting a communication malfunction between the control module and the scan tool. For the description and operation of these serial data communication circuits refer to Data Link Communications Description and Operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: - The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations Oil Level Sensor For ECM: Locations Left Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations > Page 4851 Left Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations > Page 4852 Engine Oil Level Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the left wheelhouse inner panel. Important: Clean the area around the sensor. Do not allow debris to enter the engine. 2. Disconnect the oil pressure sensor electrical connector. 3. Using J 41712, remove the oil pressure sensor (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 4856 Installation Procedure 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 41712, install the oil pressure sensor (1). Tighten the sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector. 4. Install the left wheelhouse inner panel. 5. Check and add engine oil if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-02-118-002 > Feb > 05 > Steering - 'Service Rear Wheel Steering' Message Body Control Module: Customer Interest Steering - 'Service Rear Wheel Steering' Message Bulletin No.: 05-02-118-002 Date: February 03, 2005 TECHNICAL Subject: DTC C0455, "Service Rear Wheel Steering", System Jumps from 4-Wheel Steer to 2-Wheel Steer (Reprogram BCM) Models: 2003-2005 Chevrolet Silverado, Suburban 2003-2005 GMC Sierra, Yukon XL with 4-Wheel Steer (RPO NYS) Condition Some customers may comment that the system will jump from 4-wheel steer to 2-wheel steer and the DIC displays the message "Service Rear Wheel Steering". Diagnosis will show DTC C0455-Front Steering Position Sensor malfunction. Cause This condition may be caused by a Class2 communication issue. Correction Reprogram the BCM. 2005 Model Year Vehicles: New software calibration, P/N 15248410, was released on TIS version 12 - broadcast to dealers on December 4, 2004. 2003-2004 Model Year Vehicles: New software calibration, P/N 15259330 ('03 Model Year) and P/N 15259331 ('04 04 Model Year), was released on TIS version 1.75 - broadcast to dealers on January 24, 2005. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-02-118-002 > Feb > 05 > Steering - 'Service Rear Wheel Steering' Message Body Control Module: All Technical Service Bulletins Steering - 'Service Rear Wheel Steering' Message Bulletin No.: 05-02-118-002 Date: February 03, 2005 TECHNICAL Subject: DTC C0455, "Service Rear Wheel Steering", System Jumps from 4-Wheel Steer to 2-Wheel Steer (Reprogram BCM) Models: 2003-2005 Chevrolet Silverado, Suburban 2003-2005 GMC Sierra, Yukon XL with 4-Wheel Steer (RPO NYS) Condition Some customers may comment that the system will jump from 4-wheel steer to 2-wheel steer and the DIC displays the message "Service Rear Wheel Steering". Diagnosis will show DTC C0455-Front Steering Position Sensor malfunction. Cause This condition may be caused by a Class2 communication issue. Correction Reprogram the BCM. 2005 Model Year Vehicles: New software calibration, P/N 15248410, was released on TIS version 12 - broadcast to dealers on December 4, 2004. 2003-2004 Model Year Vehicles: New software calibration, P/N 15259330 ('03 Model Year) and P/N 15259331 ('04 04 Model Year), was released on TIS version 1.75 - broadcast to dealers on January 24, 2005. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 10-07-30-001C > Apr > 11 > A/T - Fluid/Oil Leak from Transmission Vent Automatic Transmission Dipstick - Dipstick Tube: All Technical Service Bulletins A/T - Fluid/Oil Leak from Transmission Vent TECHNICAL Bulletin No.: 10-07-30-001C Date: April 13, 2011 Subject: Fluid/Oil Leak During Cold Weather from Transmission Vent (Early Models-Replace Transmission Fluid Level Indicator and Install New Transmission Vent Assembly) Models: 2001-2012 Chevrolet Silverado 2500HD-3500HD Series 2001-2012 GMC Sierra 2500HD-3500HD Series Equipped with Allison(R) LCT 1000 Automatic Transmission (RPOs M74, MW7) Supercede: This bulletin is being revised to add the 2012 model year and update information. Please discard Corporate Bulletin Number 10-07-30-001B (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a small red fluid/oil leak during cold weather. Upon further investigation, the technician may find a small fluid leak in the area at the back of the transmission by the vent. Cause This condition may be caused by fluid being discharged out the transmission vent due to a low transmission fluid fill. During extreme cold weather, (approximately -25°C (-15°F or colder), low fluid fill can cause the transmission pump to ingest air which can aerate the fluid and push some fluid out the vent. Correction On 2001 through 2012 models, verify the transmission is full of fluid. Follow the SI fluid checking procedure to PROPERLY check the transmission fluid level using the Hot Check Procedure. Important Ensure that the fluid level is at the top of the HOT band when the transmission fluid temperature is 79°C (175°F). Refer to SI Document ID# 2408059 for the proper fluid level checking procedure. Note Only on 2001-2004 models, replace the transmission fluid indicator (dipstick) with a new vented indicator, P/N 15794381. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 10-07-30-001C > Apr > 11 > A/T - Fluid/Oil Leak from Transmission Vent > Page 4876 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 10-07-30-001C > Apr > 11 > A/T - Fluid/Oil Leak from Transmission Vent > Page 4882 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4883 Body Control Module: Locations Body Control Module (BCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4884 Body Control Module (BCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4887 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4888 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4889 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4890 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4891 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4892 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4893 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4894 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4895 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4896 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4897 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4898 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4899 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4900 Body Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4901 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4902 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4903 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4904 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4905 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4906 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4907 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4908 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4909 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4910 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4911 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4912 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4913 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4914 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4915 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4916 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4917 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4918 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4919 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4920 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4921 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4922 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4923 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4924 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4925 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4926 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4927 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4928 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4929 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4930 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4931 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4932 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4933 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4934 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4935 Body Control Module: Connector Views Body Control Module (BCM) - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4936 Body Control Module (BCM) - C2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4937 Body Control Module (BCM) - C2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4938 Body Control Module (BCM) - C2 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4939 Body Control Module (BCM) - C3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4940 Body Control Module (BCM) - C3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4941 Body Control Module (BCM) - C4 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4942 Body Control Module (BCM) - C4 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4943 Body Control Module (BCM) - C5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4944 Body Control Module (BCM) - C6 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4945 Body Control Module (BCM) - C6 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4946 Body Control Module: Electrical Diagrams Door Control Module Diagram 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4947 Door Control Module Diagram 2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4948 Door Control Module Diagram 2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4949 Door Control Module Diagram 3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4950 Door Control Module Diagram 3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 4951 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The body control module (BCM) monitors several inputs in order to arm and disarm the CTD system. The BCM controls the alarm function outputs. When the BCM detects an unauthorized entry (any door opened), the BCM applies ground to the horn, the park lamp and the headlamp relays. The BCM will send messages to the security telltale in the instrument cluster through the Class 2 serial data link. The BCM has the following 8 basic modes for operating the CTD system. The more detailed descriptions are below. - Off state - Idle state - Disarmed state - Ready-to-arm state - Arm initiated state - Arm delay state - Armed state - Alarm state The BCM has the following 6 discrete inputs in order to monitor the CTD system: - Ignition 1 - Driver door latch (door jamb) switch - Passenger door latch (door jamb) switch - Door lock relay - Door key switch - Passenger door unlock relay The BCM applies ground once per second for approximately 2 minutes, or until a valid input to disarm the system is received by the BCM. The Body Control Module (BCM) contains the theft deterrent system logic. The BCM reads the Passlock(TM) data from the Passlock(TM) sensor. If the Passlock(TM) data is correct, the BCM will pass theft. The BCM will then transmit the fuel continue password to the VCM/PCM. During the tamper mode the vehicle may start. The vehicle will then stall. If the BCM receives the wrong Passlock(TM) data, the VTD will immediately go into the tamper mode. The tamper mode will lock-out the vehicle fuel injectors for 10 minutes. The SECURITY indicator will flash while the VTD is in the tamper mode. If the Passlock(TM) sensor sends a correct password to the BCM when the ignition is in the ON position, the BCM will send a fuel enable signal to the VCM/PCM. The VCM/PCM will not disable the fuel due to any BCM message for the remainder of the ignition cycle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION The procedures below are designed to set-up the body control module (BCM) correctly during BCM related service. Before you start, read these procedures carefully and completely. IMPORTANT: The following procedures must be followed: 1. Programming the BCM. 2. Programming Theft Deterrent System Components, if equipped with Passlock System. PROGRAMMING THE BCM IMPORTANT: After the procedure is completed, the personalization settings of the BCM are set to a default setting. Inform the customer that the personalization must be set again. Perform the BCM special function Request BCM Info. for service programming system (SPS), then follow the SPS instructions. Refer to Service Programming System (SPS) in Programming. PROGRAMMING THEFT DETERRENT SYSTEM COMPONENTS IMPORTANT: This procedure has to be performed only for vehicles equipped with Passlock System. Perform the Programming Theft Deterrent System Components in Theft Deterrent after successfully finishing the Setup New BCM procedure. If the Programming Theft Deterrent System Components in the Theft Deterrent procedure is not performed after a BCM replacement, one of the following conditions will occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank or start. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON, with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 4954 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable(s). 2. Remove the knee bolster. 3. Disconnect the brown connector. 4. Disconnect all other connectors (1). 5. Remove the BCM from the sliding bracket. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 4955 1. Slide the BCM onto the bracket. 2. Connect all the connectors (1) except the brown connector. 3. Connect the brown connector. 4. Install the knee bolster. 5. Connect the negative battery cable(s). 6. Reprogram the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. 7. Perform the Passlock Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 4960 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 4961 Engine Control Module: Technical Service Bulletins Diesel Engine - Damage Due To Power-Up Devices INFORMATION Bulletin No.: 06-06-01-007F Date: March 31, 2010 Subject: Information On Identifying Duramax(TM) Diesel LB7, LLY, LMM, LBZ Overpower Engine Breakdown or Non-Function Due to Aftermarket Power-Up Devices vs. Non Overpower Engine Non-Function of Pistons, Cylinders, Valvetrain Components and/or Turbocharger DTC P003A Set Models: 2001-2010 Chevrolet Silverado 2003-2009 Chevrolet Kodiak 2006-2010 Chevrolet Express 2001-2010 GMC Sierra 2003-2009 GMC TopKick 2006-2010 GMC Savana Equipped With Duramax(TM) Turbocharged Diesel Engine RPOs LB7, LLY, LMM, LBZ Please Refer to GMVIS Supercede: This bulletin is being revised to add text to the end of the Caution statement. Please discard Corporate Bulletin Number 06-06-01-007E (Section 06 - Engine/Propulsion System). Caution Customers should be informed if a hard part failure is observed in the engine, transmission, transfer case and/or other driveline components, it is likely that powertrain components were weakened to the point of premature failure, while subjected to the higher stresses from Aftermarket Power-Up Devices. Failures associated with the installation of Aftermarket Power-Up Devices, which have been verified, are not covered under the terms of the New Vehicle Warranty. In the majority of these cases, the Fixed Operations Manager (FOM) (in Canada, Warranty Manager) should be contacted and the remaining portion of the powertrain portion of the New Vehicle Warranty blocked. GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage. General Motors Position On Aftermarket Power-Up Devices Important General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. Refer to Service Bulletin Number 04-06-04-054A or newer - Warranty Admin. - Non-GM Parts and Accessories (Aftermarket). Important For further information on aftermarket power-up kits, refer to February 2006 Emerging Issues Course Number 10206.02D. In Canada, information on aftermarket power-up kits was covered in the April 2006 TAC TALK program. Aftermarket power-up devices are non-approved by General Motors. These devices are usually piggy-backed in the main engine harness or remain connected to the diagnostic connector to upload the calibration to the ECM. Recent warranty reviews of returned engines show engine breakdown or non-function due to power-up devices that are utilized for increased horsepower and torque. The following information will assist technicians in identifying overpower engine breakdown or non-function due to aftermarket power-up devices vs. non overpower engine breakdown or non-function. Non-GM parts can alter the design of the vehicle. GM dealers need to be aware of the quality of parts being installed on vehicles. If failure occurs as a result of installation of sub-par parts, warranty coverage may be denied. Refer to Service Bulletin Number 04-06-04-054A or newer Warranty Admin. - Non-GM Parts and Accessories (Aftermarket). Installed Power-Up Kit Aftermarket power-up kits have become a very popular add on for performance-minded customers. These devices can add horsepower and torque and can add additional stress to the engine. These aftermarket calibrations take the Duramax(TM) powertrain outside of its design torque and horsepower rating. They do this by altering air/fuel ratios and injector timing, resulting in excessive cylinder pressure and temperature. When these calibrated parameters are altered, it will upset the design balance and can lead to a reduction of engine life expectancy. Generally, in inspection of Duramax(TM) engine failure due to power-up failures, two or more cylinders will be affected. Installed Power-Up Kit - Once installed, the calibration may mask itself with the factory original calibration ID and may remain the same. Refer to Service Bulletin Number 08-06-04-006F or newer - Information on Identifying Non-GM Calibration Usage for LMM Duramax(TM) Diesel Engine. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 4962 - A Tech 2(R) will not positively enable you to identify the use of a power-up device. - Some companies that offer power-up devices claim increases of 150 or more horsepower and 300 or more lb/ft pounds of torque. - A vehicle that is used to the power-up device potential 100% of the time will see earlier engine wear and breakdown. - A vehicle that takes advantage of additional power, but on a less frequent basis, may not see premature engine wear and breakdown until later in the engine's life. - A vehicle not pushed to its limits of the power-up device often may not encounter premature wear and breakdown until after the engine is out of warranty. Duramax(TM) Powertrain Horsepower / Torque Ratings The following horsepower and torque increase over the past years required new internal components to accommodate the increase. - LB7 - 300 hp with 520 ft/lb of torque for model years 2000-2004 - LLY - 310 hp with 605 ft/lb of torque for model years 2004-2008 - LBZ - 360 hp with 650 ft/lb of torque for model year 2006-2008 - LMM - 365 hp with 660 ft/lb of torque for model year 2007-2009 LBZ Improvements To reliably achieve an increase in 50 horsepower with 45 ft/lb torque, the Duramax (TM) diesel had to be revised in many areas. A few of the revisions on the 2006 LBZ were: - New pistons with a revised compression ratio. - Wrist pins that are larger in diameter. - Connecting rods with added material to increase the I section strength. - Engine block and machining changes - Cylinder heads Duramax(TM) Life Expectancy The Duramax(TM) 6.6L V8 Turbo Diesel Engine is sold with a warranty of 100,000 miles/160,000 kilometers. The Duramax(TM) has been tested to survive upwards of 200,000 miles/320,000 kilometers. The Duramax(TM) powertrain is designed for reliability, peak horsepower and torque within its design limits. When a customer installs a power-up device, it drastically reduces the mileage ratings. Important Cylinder Wall Spotting (commonly referred to leopard spots) is from the induction hardening process of the top 1/3 of the cylinder wall. This is normal for the Duramax (TM) Diesel. Identifying Fuel Related Aftermarket Power-Up Devices Aftermarket companies have developed a performance pressure relief fuel valve for Duramax(TM) diesel engines. Refer to above graphic illustration. The performance pressure relief fuel valve attaches to the fuel rail in place of the OEM valve and will not allow any fuel return to the tank, giving 100% of the fuel to be available for additional engine performance. This may cause additional fuel related driveability concerns and may set the following DTCs: - DTC P1093 Fuel Rail Pressure (FRP) Low During Power Enrichment - DTC P0087 Fuel Rail Pressure (FRP) Too Low Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 4963 Aftermarket companies have developed a replacement performance/economy fuel injector nozzle. Refer to above illustration. The performance/economy fuel injector nozzles replace the OEM fuel injector nozzles. The aftermarket companies claim increased horsepower, improved fuel atomization, lower exhaust gas temperatures and increase fuel economy. This may cause additional fuel related driveability concerns and may cause internal engine damage to the pistons and fuel injector nozzles. Identifying Overpower Engine Premature Wear and Breakdown When premature wear and breakdown is encountered due to an aftermarket power-up device, it has some very specific characteristics to the internal engine components. The following list will assist in identifying these characteristics as you tear down the engine. - Pistons will be cracked in the lip area, or a hole in the pistons. - Pistons can also be melted on the lip of the combustion bowl, or the top of the pistons can be melted. - Crosshatch will be polished off the cylinder wall in the major thrust face of cylinder below ring belt travel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 4964 - Piston pin bore will show signs of scoring, the wrist pins will be discolored, and can have oil coking on them. The connecting rod bushing surface will have accelerated wear. The above illustration shows a connecting rod bushing. - Oil coking on the underside of the piston between the wrist pin bosses. - Signs of bearing fretting will also be noticed on the connecting rod and main bearing caps. Refer to the above illustration for fretting of main bearing cap 1 and back side of connection rod bearing 2. - Excessive heat in engine compartment caused by overpower device. Refer to above illustration (1). Non Overpower Engine Premature Wear and Breakdown The following pictures show results of overheat, overspeed, low/no oil pressure or injector breakdown and how they differ from aftermarket power-up device premature wear and breakdown. Engine Overheat Overheat can be caused by a loss of coolant or a general cooling system failure. Some of the indicators of overheat are: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 4965 - Melted pistons. - Head gasket breakdown or non-function. - Warped cylinder heads. - Crankshaft and connecting rod discolored. Engine Overspeed Causes If an engine has been run faster than design capability (redline), and has caused damage as a result, it may be a result of one of the following conditions: - Leaking or failed turbocharger (TC) oil seals. - Oil evident in the intake runners and compressor side of the TC. - Starting fluid use or alternative fuel added to the engine such as ether. Engine Overspeed Results The following are indicators that an overspeed event took place: - Valve train damage. - Pushrods that are bent (4). - Broken valve bridge buttons after cylinder head removal (2). - Rocker arm tip damage (1). - Dry or rusted cylinders from the use of ether, propane or nitrous oxide. - Piston to valve contact. - Cam gear pin shear. Lack of Oil Pressure Lack of lubrication causes rapid bearing wear or bearing to seize. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 4966 Bearing failure. Spun main bearings. Engine Premature Wear and Breakdown Due to Improper Function of Fuel Injector A fuel injector may fracture a piston or melt a piston but the damage will be limited to that cylinder only and all other pistons and cylinder walls are OK. In some cases hydraulic lock will occur on the suspected cylinder with an over-fueling fuel injector. Hydraulic lock on the suspected cylinder will cause a bent connecting rod. This can be verified with piston protrusion measurements. 2007-2010 RPO LMM Only Turbocharger DTC P003A Set General Motors has identified a turbocharger (TC) failure mode involving Power-Up Kits that causes soot leakage and DTC P003A to be set. The Power-Up Kits create an overtemperature condition from the increased exhaust gas temperatures that results in a permanent and excessive turbine housing distortion at the TC case halves. 1. A technician may observe one or more of the following conditions: - DTC P003A being set as Current or in History. - An unusual odor emanating from the TC due to an overtemperature condition. - Soot leaking and accumulating at the V-band clamp that secures the TC case halves together. - Limited or unresponsive travel when Commanding the TC Vane Pos. Ctrl. Solenoid ON and OFF with a scan tool. 2. If DTC P003A is found as Current or in History, OR there is evidence of soot leakage (1) in the area of the V-band clamp (1), then technicians MUST verify if the engine control module (ECM) has a Power-Up Kit aftermarket calibration installed or an aftermarket hardware device has been installed. Refer to Service Bulletin Number 08-06-04-006F or newer for the calibration verification information and procedures. How to Handle a Suspect Engine Failure Due to a Power-Up Device Dealers should not automatically decline warranty assistance on engine failures due to the fact that a power-up device or modification is evident or suspected. The technician must identify that the failure is due to a power-up device by teardown analysis and diagnosis of the engine components. The following steps should be taken if an engine failure occurs and it is suspected that the modification or addition of a power-up device maybe the cause of the engine failure. If unclear of this process or direction feel free to contact your Fixed Operations Manager (in Canada, Warranty Manager) for further support. 1. The technician should use proper engine diagnostics to lead him/her to the failed engine components. The Aftermarket Power-Up Kit Check List should be followed and if it is determined that at least three of the Aftermarket Power-Up Kit Check List items match the engine component failures then it can be decided that the failure is not a warrantable claim. 2. Engine failures that meet at least three criteria of the Aftermarket Power-Up Kit Check List are considered failures that are not manufacturer's defects in workmanship or materials. 3. The dealership should contact the PQC, open a case to review the findings and make the final decision on warranty coverage. The Fixed Operations Manager (in Canada, Warranty Manager) should be notified of the PQC decision. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 4967 4. Denied claims should be documented as follows: 1. The Aftermarket Power-Up Kit Check List completed with the technicians detailed written findings of the diagnosis on the repair order and retained in the repair order file. 2. Photographs of the failed parts should be retained in the repair order file. 5. The customer should be advised that the failure of their engine was not due to a manufacturer's defect in workmanship or materials and therefore the warranty claim is denied on this failure. Aftermarket Power-Up Kit Check List Important Print and use this aftermarket power-up kit check list when performing an engine disassembly investigation of overpower engine breakdown or non-function. Retain a copy of this checklist and photographs of the failed parts in the repair order file. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4968 LF Of The Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 Engine Control Module: Diagrams Engine Control Module (ECM) - C1 Engine Control Module (ECM) - C1 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4971 Engine Control Module (ECM) - C1 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4972 Engine Control Module (ECM) - C1 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4973 Engine Control Module (ECM) - C1 Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4974 Engine Control Module: Diagrams Engine Control Module (ECM) - C2 Engine Control Module (ECM) - C2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4975 Engine Control Module (ECM) - C2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4976 Engine Control Module (ECM) - C2 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4977 Engine Control Module (ECM) - C2 Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4978 Engine Control Module (ECM) - C2 Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4979 Engine Control Module: Diagrams Engine Control Module (ECM) - C3 Engine Control Module (ECM) - C3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4980 Engine Control Module (ECM) - C3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4981 Engine Control Module (ECM) - C3 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Engine Control Module (ECM) - C1 > Page 4982 Engine Control Module (ECM) - C3 Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Passlock Function Engine Control Module: Description and Operation Passlock Function VEHICLE/POWERTRAIN CONTROL MODULE The VCM/PCM communicates with the BCM over the Class 2 serial data line. When the BCM determines a no start condition, it sends a Class 2 serial data password to the VCM/PCM in order to disable the fuel injection system. If the BCM receives the expected voltage from the Passlock(TM) sensor, the BCM sends a class 2 serial data password to the VCM/PCM in order to enable the fuel injection system. The VCM/PCM then allows the vehicle to start correctly. If the Class 2 serial data password from the BCM to the VCM/PCM is not within the Vehicle Security Status Message, the fuel injectors will shut OFF during a start attempt. The SECURITY telltale will be illuminated for 10 minutes. If the VCM/PCM does not receive the same password from the BCM as the last learned one, the vehicle will start and then stalls due to the Fuel Lockout. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Passlock Function > Page 4985 Engine Control Module: Description and Operation Engine Control Module (ECM) ENGINE CONTROL MODULE (ECM) DESCRIPTION The engine control module (ECM) processes the various input information. The ECM sends the necessary electrical responses to control fuel delivery. The input information has an interrelation to more than one output. One failed input can affect more than one systems operation. Diagnostic System Check - Computers and Control Systems The Diagnostic System Check Computers and Control Systems is an organized approach to identify a problem caused by an electronic engine control system malfunction. This diagnostic check must be the starting point for any driveability complaint diagnosis. The diagnostic directs the technician to the next logical step in diagnosing the complaint. Use the Engine Scan Tool Data Definitions list for a comparison after fulfilling the following items: Complete the Diagnostic System Check-Computers and Control Systems. - Confirm that the on-board diagnostics are functioning properly. - Confirm there are no diagnostic trouble codes. The Engine Scan Tool Definitions are an average of display values recorded from normal operating vehicles. The definitions intend to represent what a normal functioning system should display. IMPORTANT: Do not use a scan tool that displays faulty data. Report the problem to the manufacturer. Using a malfunctioning scan tool can result in misdiagnosis and unnecessary parts replacement. Use only the parameters listed in the Engine Scan Tool Data Definitions for diagnosis. When a scan tool reads other parameters, General Motors recommends not using the values for use in diagnosis. For more description on the values and the use of the scan tool to diagnose the ECM inputs, refer to the applicable diagnostic file. When all the values are within the range illustrated in the Engine Scan Tool Data Definitions, refer to Symptoms - Computers and Control Systems. Control Module Communications The control module system has a computer, the engine control module (ECM), to control fuel delivery, timing, and some emission control systems. The control module system monitors a number of engine and vehicle functions and controls the following operations through the fuel injection control module (FICM): Fuel rail pressure - Fuel injector - Fuel injector pulse width The diesel ECM, located in the engine compartment, is the control center of the control module system. The engine control module used on the electronic fuel injected 6.6L diesel is referred to as a ECM. The ECM constantly looks at the information from various sensors, and controls the systems that affect vehicle performance. The ECM performs the diagnostic function of the system. The ECM can recognize operational problems, alert the driver through the MIL. Service Engine Soon, and store one or more diagnostic trouble codes (DTCs) which identify the problem areas to aid the technician in making repairs. See the specific diagnosis procedure for more information. Malfunction Indicator Lamp (MIL) Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Passlock Function > Page 4986 The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Aftermarket (Add-On) Electrical And Vacuum Equipment Any equipment installed on a vehicle after leaving the factory that connects to the electrical or vacuum systems of the vehicle defines aftermarket (Add-On) electrical and vacuum equipment. The vehicle design makes no allowances for this type of equipment. NOTE: - Do not attach add-on vacuum operated equipment to this vehicle. The use of add-on vacuum equipment may result in damage to vehicle components or systems. - Connect any add-on electrically operated equipment to the vehicle's electrical system at the battery (power and ground) in order to prevent damage to the vehicle. The add-on electrical equipment, even when installed to these strict guidelines, may still cause the powertrain system to malfunction. This may also include any equipment which is not connected to the electrical system of the vehicle such as portable telephones and radios. Therefore, the first step in diagnosing any powertrain problem is to eliminate all of the aftermarket electrical equipment from the vehicle. After this is done, if the problem still exists, diagnose the problem in the normal manner. Computers and Control Systems Information The driveability and emissions information describes the function and operation of the control module. The emphasis is placed on the diagnosis and repair of problems related to the system. Engine Components, Wiring Diagrams, and Diagnostic Trouble Code (DTC) tables: The Component Locations - The Wiring Diagrams - The Control Module Terminal End View and Terminal Definitions - The Diagnostic System Check - Computers and Control Systems - The Diagnostic Trouble Code (DTC) tables The Component System includes the following items: The component and circuit description - The On-vehicle service for each subsystem - The Functional checks with the diagnostic tables - How To Use Electrical Systems Diagnostic Information The DTCs also contain the diagnostic support information containing the circuit or the system information, and helpful diagnostic information. Wiring Harness Service The control module harness electrically connects the control module to the various solenoids, switches, and sensors in the vehicle engine compartment and passenger compartment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Passlock Function > Page 4987 Replace the wire harnesses with the proper part number replacement. When splicing signal wires into a harness, use the wiring that has high temperature insulation. Consider the low amperage and voltage levels utilized in the powertrain control systems. Make the best possible bond at all splices. Use rosin-core solder in these areas. Molded-on connectors require complete replacement of the connector. Splice a new connector into the harness. Replacement connectors and terminals are listed in Group 8.965 in the Standard Parts Catalog. Connectors and Terminals In order to prevent shorting between opposite terminals, use care when probing a connector and when replacing terminals. Damage to the components could result. Always use jumper wires between connectors for circuit checking. Never probe through the Weather-Pack seals. The J 35616-B Connector Test Adapter Kit , or the equivalent, contains an assortment of flexible connectors used in order to probe the terminals during the diagnosis. The fuse remover and the BT-8616 Test Tool, or the equivalent, is used for removing a fuse and to adapt the fuse holder to a meter for diagnosis. Open circuits are often difficult to locate by sight because oxidation or terminal misalignment are hidden by the connectors. Merely wiggling a connector on a sensor or in the wiring harness may temporarily correct the open circuit. Oxidized or loose connections may cause intermittent problems. Be certain the type of connector and terminal before making any connector or terminal repair. Weather-Pack and Com-Pack III terminals look similar, but are serviced differently. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Passlock Function > Page 4988 Engine Control Module: Description and Operation Turbocharger ENGINE CONTROL MODULE (ECM) The ECM controls all turbocharger control functions. The ECM monitors information from various sensor inputs that include the following: - The accelerator pedal position (APP) sensor - The engine coolant temperature (ECT) sensor - The mass airflow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The boost pressure sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 4989 Engine Control Module: Service and Repair ENGINE CONTROL MODULE (ECM) REPLACEMENT Service of the engine control module (ECM) should consist of either replacement of the ECM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the ECM to be replaced, the replacement ECM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty ECM and install the new service ECM. REMOVAL PROCEDURE IMPORTANT: - To prevent internal ECM damage, the ignition switch must be OFF when disconnecting or connecting power to the ECM. - Remove any debris from the ECM connector surfaces before servicing the ECM. Inspect the ECM module connector gaskets when diagnosing or replacing the ECM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the ECM. - The replacement ECM must programmed. - It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100%. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5000km (3,000 mi) from the last engine oil change. 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 2. Disconnect the negative battery cable. 3. Disconnect the ECM electrical connectors (2). 4. Release the ECM cover retaining tabs. 5. Remove the ECM cover from the bracket. 6. Remove the ECM cover. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 4990 1. Install the ECM. IMPORTANT: The cover must be fully installed prior to the electrical connections being made to ensure the ECM is fully seated in the bracket. 2. Install the ECM cover to the bracket. 3. Engage the ECM cover retaining tabs. 4. Connect the ECM electrical connectors (2). 5. Connect the negative battery cable. 6. If a NEW ECM was installed, program the ECM. Refer to Service Programming System (SPS) in Programming. See: Testing and Inspection/Programming and Relearning 7. Perform the turbocharger learn procedure. Refer to Turbocharger Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4995 Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4996 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SYSTEM DESCRIPTION The accelerator pedal position (APP) system along with the vehicle electronics and components is used to calculate and control the amount of acceleration and deceleration via fuel injector control. This eliminates the need for a mechanical cable attachment from the accelerator pedal to a throttle body. The APP system includes, but is not limited to, the following components : - The accelerator pedal position (APP) sensor assembly - The engine control module (ECM) Accelerator Pedal Position (APP) Sensor The accelerator pedal position (APP) sensor is mounted on the accelerator pedal control assembly. The sensor is made up of 3 individual sensors within one housing. Three separate signal, low reference, and 5-volt reference circuits are used in order to interface the accelerator pedal sensor assembly with the ECM. Each sensor has a unique functionality to determine pedal position. The ECM uses the APP sensor to determine the amount of acceleration or deceleration desired by the person driving the vehicle. The APP sensor 1 voltage should increase as the accelerator pedal is depressed, from below 1.0 volt at 0 pedal travel to above 2 volts at 100 percent pedal travel. APP sensor 2 voltage should decrease from above 4 volts at 0 pedal travel to below 3.0 volts at 100 percent pedal travel. APP sensor 3 voltage should decrease from above 3.8 volts at 0 percent pedal travel to below 3.3 volts at 100 percent pedal travel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4997 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION (APP) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector. 3. Reposition the carpet to access the lower nut. 4. Remove the accelerator pedal nuts. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4998 1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Service Precautions. 2. Install the accelerator pedal nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Connect the APP sensor electrical connector. 4. Reposition the carpet. 5. Install the CPA retainer. 6. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 7. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle and a wide open throttle (WOT). 8. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 9. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Mass Air Flow (MAF) Sensor: Locations Right Side Of The Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 5002 Right Side Of Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 5003 Intake Air Temperature (IAT)/Mass Airflow (MAF) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 5004 Mass Air Flow (MAF) Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector (1). 2. Remove the MAF/IAT sensor TORX(R) screws. 3. Remove the MAF/IAT sensor (1). INSTALLATION PROCEDURE 1. Install the MAF/IAT sensor (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 5005 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the MAF/IAT sensor TORX(R) screws. Tighten Tighten the screws to 8 N.m (70 lb in). 3. Connect the MAF/IAT sensor electrical connector (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations Barometric Pressure Sensor: Locations Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 5009 Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 5010 BARO Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 5011 Barometric Pressure Sensor: Service and Repair BAROMETRIC PRESSURE (BARO) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the barometric pressure (BARO) sensor electrical connector. 2. Push the BARO sensor (1) downward in order to remove it from the bracket. INSTALLATION PROCEDURE 1. Push the BARO sensor (1) upward in order to remove it from the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 5012 2. Connect the BARO sensor electrical connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Brake Pressure Switch > Component Information > Locations Chassis And License Lamp Harnesses Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Right Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5019 Camshaft Position (CMP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Replacement CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the cooling fan pulley. 2. Remove the camshaft position (CMP) sensor bolt. 3. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Lubricate the CMP sensor O-ring with clean engine oil. 2. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the CMP sensor bolt. Tighten Tighten the bolt to 10 N.m (89 lb in). 4. Install the cooling fan pulley. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement > Page 5022 Camshaft Position Sensor: Service and Repair Camshaft Reluctor Replacement Camshaft Reluctor Replacement Removal Procedure Notice: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 1. Remove the engine front cover. 2. While holding the secondary oil pump shaft with a hex driver, remove the oil pump driven gear nut. 3. Remove the oil pump driven gear. 4. Important: DO NOT remove the reluctor from the oil pump drive gear. The reluctor is timed to the gear and once removed the correct timing will be lost. Remove the oil pump drive gear and crankshaft sensor reluctor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement > Page 5023 5. Remove the camshaft reluctor screws. 6. Remove the camshaft reluctor. 7. Clean and Inspect the camshaft reluctor for damage. Replace the reluctor if damage is found. Installation Procedure 1. Position the camshaft reluctor to the camshaft gear. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the camshaft reluctor bolts. Tighten the bolts to 9 Nm (80 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement > Page 5024 3. Important: Do not damage the teeth on the reluctor. Install the oil pump drive gear and reluctor to the crankshaft. 4. Install the oil pump driven gear. 5. While holding the secondary oil pump shaft with a hex driver, install the oil pump driven gear nut. Tighten the nut to 100 Nm (74 ft. lbs.). 6. Install the engine front cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations SEO Harness Routing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Upper Front of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 5031 Engine Coolant Temperature (ECT) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 5032 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the coolant to a level below the engine coolant temperature (ECT) sensor. 2. Disconnect the ECT sensor electrical connector. 3. Remove the ECT sensor (1). INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 5033 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor (1). Tighten Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the ECT sensor electrical connector. 4. Fill the cooling system, if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Starter Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5037 Right Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5038 Crankshaft Position (CKP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5039 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the right wheelhouse panel. 3. Disconnect the crankshaft position (CKP) sensor electrical connector. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. 6. If necessary, remove the CKP sensor spacer bolts. 7. If necessary, remove the CKP sensor spacer. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5040 1. If necessary, lubricate a NEW CKP spacer O-ring with clean engine oil. 2. If necessary, install the NEW O-ring to the CKP sensor spacer. IMPORTANT: The crankshaft position sensor spacers are machined with different timing positions. However, if the crankshaft position sensor spacer requires replacement, replace with a grade "C" spacer. 3. If necessary, install the CKP sensor spacer. NOTE: Refer to Fastener Notice in Service Precautions. 4. If necessary, install the CKP sensor spacer bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). 5. Lubricate a NEW CKP sensor O-ring with clean engine oil. 6. Install the NEW O-ring to the CKP sensor. 7. Install the CKP sensor. 8. Install the CKP sensor bolt. Tighten Tighten the bolt to 10 N.m (89 lb in). 9. Connect the CKP sensor electrical connector. 10. Install the right wheelhouse panel. 11. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Fuel Tank - Primary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 5044 Fuel Tank - Secondary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 5045 Fuel Level Sensor: Diagrams Fuel Level Sensor - Primary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 5046 Fuel Level Sensor - Secondary W/Dual Tanks Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 5047 Fuel Level Sensor - Primary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 5048 Fuel Level Sensor - Secondary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 5049 Fuel Level Sensor: Description and Operation FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The engine control module (ECM) sends the fuel level information via the class 2 circuit to the instrument panel cluster (IPC). This information is used for the instrument panel (I/P) fuel gage and the low fuel warning indicator, if applicable. The ECM also monitors the fuel level input for various diagnostics. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 5050 Fuel Level Sensor: Service and Repair FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel level sensor electrical connector (1). 3. Remove the sensor retaining clip (3). 4. Squeeze the locking tangs (2) and remove the fuel level sensor. INSTALLATION PROCEDURE 1. Install the fuel level sensor. 2. Install the sensor retaining clip (3). 3. Connect the sensor electrical connector (1). 4. Install the sending unit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Pressure Sensor > Component Information > Locations Fuel Pressure Sensor: Locations Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Pressure Sensor > Component Information > Locations > Page 5054 Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Pressure Sensor > Component Information > Locations > Page 5055 Fuel Pressure Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Pressure Sensor > Component Information > Locations > Page 5056 Fuel Pressure Sensor: Service and Repair FUEL RAIL PRESSURE (FRP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet duct. 2. Remove the exhaust gas recirculation (EGR) cooler tube. 3. Disconnect the fuel rail pressure sensor electrical connector. 4. Prior to removal, clean the fuel pressure sensor and surrounding area thoroughly with solvent, such as GM P/N 12377981 (Canadian P/N 10953463) or equivalent. 5. Using compressed air, thoroughly blow dry the sensor and surrounding area. 6. Remove the fuel pressure sensor (1). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Pressure Sensor > Component Information > Locations > Page 5057 1. Install the fuel pressure sensor (1). Tighten Tighten the sensor to 70 N.m (52 lb ft). 2. Connect the fuel rail pressure sensor electrical connector. 3. Install the EGR cooler tube. 4. Install the air cleaner outlet duct. 5. Prime the fuel system. Refer to Fuel System Priming. 6. Start the engine. If the engine stalls, repeat the above step. 7. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Intake Air Temperature (IAT) Sensor: Locations Intake Air Temperature (IAT) Sensor is part of the Mass Air Flow (MAF) Sensor and is in the air induction tube. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 5061 Intake Air Temperature (IAT)/Mass Airflow (MAF) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 5062 Intake Air Temperature (IAT) Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector (1). 2. Remove the MAF/IAT sensor TORX(R) screws. 3. Remove the MAF/IAT sensor (1). INSTALLATION PROCEDURE 1. Install the MAF/IAT sensor (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 5063 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the MAF/IAT sensor TORX(R) screws. Tighten Tighten the screws to 8 N.m (70 lb in). 3. Connect the MAF/IAT sensor electrical connector (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations Oil Level Sensor For ECM: Locations Left Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations > Page 5067 Left Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations > Page 5068 Engine Oil Level Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement ^ Tools Required J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the left wheelhouse inner panel. Important: Clean the area around the sensor. Do not allow debris to enter the engine. 2. Disconnect the oil pressure sensor electrical connector. 3. Using J 41712, remove the oil pressure sensor (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Page 5072 Installation Procedure 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Using J 41712, install the oil pressure sensor (1). Tighten the sensor to 30 Nm (22 ft. lbs.). 3. Connect the oil pressure sensor electrical connector. 4. Install the left wheelhouse inner panel. 5. Check and add engine oil if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start Transmission Position Switch/Sensor: Customer Interest A/T - Slow/No Gear Engagement/Engine No Start Bulletin No.: 02-07-30-011C Date: June 21, 2004 TECHNICAL Subject: Slow or No Engagement of Automatic Transmission, No Start, Blank PRNDL Display, Flashing PRNDL, DTC P0708, P0872, P0847, P0875, P1711, P1713 or U1000 Set (Diagnose Condition, Repair According to Procedure) Models: 2001-2004 Chevrolet Silverado 2001-2004 GMC Sierra with Allison(R) LCT1000 Automatic Transmission (RPO M74) and 6.6L Duramax(TM) Diesel Engine (RPO LB7) or 8.1L Gas Engine (RPO L18) Supercede: This bulletin is being revised to add model years and additional model information and add graphics. Please discard Corporate Bulletin Number 02-07-30-011B (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions. ^ The PRNDL display is flashing. ^ The engine will not start. ^ The "Service Engine Soon" Indicator lamp is illuminated. ^ The transmission does not shift properly. ^ The vehicle will not move, transmission will not engage. Cause Moisture contamination within the Park Neutral Position (PNP) Switch may cause this condition. This is sometimes referred to as the Neutral Start Back-up (NSBU) Switch. On a left turn, water spray from the left front tire is directed directly at this switch. Proper installation of the "Front Shield" and "Rear Shield" are essential for proper repairs. Technician Diagnosis This bulletin ONLY applies to vehicles equipped with a two connector PNP switch as shown above. A complete and through diagnosis must be performed by a qualified electrical technician to determine the cause and avoid needless replacement of good components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 5081 Important: The Transmission Control Module (TCM) and or the Pressure Switch Manifold (PSM) should NOT be replaced unless properly diagnosed. They are probably not the cause of the concern. It is often assumed the module is the cause of the concern when, in fact, it is another component or the wiring between the components that causes the concern. Important: Remember, everything starts with a properly operating Neutral Start Back Up (NSBU) switch. The NSBU switch has been incorporated into what is now called the Park Neutral Position (PNP) switch. If the PNP switch does not provide the proper voltage signal to the module indicating the transmission is in either Park or Neutral, the module will not allow the starter operation. After the engine is started, and the shift lever is moved to either Reverse or one of the drive positions, the range selected portion of the PNP switch portion provides a voltage input to the module as to what range the driver has manually selected for transmission operation. The module then controls pressures, shift points and other transmission functions based on the voltage input received from the range portion of the PNP switch. The technician may find one or more of the following conditions. The list of these conditions does not imply any type of frequency or order. They are random events and may occur in any order. ^ DTC P0708, Neutral start/backup (PNP or NSBU) switch ^ DTC P0847, Pressure Switch Manifold (PSM) ^ DTC P0872, Pressure Switch Manifold (PSM) ^ DTC P0875, Pressure Switch Manifold (PSM) ^ DTC P1711, Pressure Switch Manifold (PSM) ^ DTC P1713, Pressure Switch Manifold (PSM) ^ DTC U1000, Serial Data Communications ^ Blank PRNDL Display ^ Flashing PRNDL Display ^ Slow or No Engagement of Automatic Transmission Blank PRNDL Display A blank PRNDL display may indicate a condition with the PNP switch and/or one or more of the four signal circuits from the PNP to the TCM. 1. Pin A, Circuit 771 (BLK/WHT) 2. Pin B, Circuit 773 (GRA) 3. Pin C, Circuit 776 (WHT) 4. Pin D, Circuit 772 (YEL) Or, a blank PRNDL display may also occur if an out of line condition exists with the Serial Data Circuit (CKT 2470, yellow wire) from the TCM to Splice Pack 205. Diagnostic Tip 1. Connect the Tech 2(R) to the vehicle. 2. Power up the Tech 2(R). 3. Does the Tech 2(R) communicate with the TCM? If not, inspect the serial data circuit, CKT 2470 (Yellow wire), between the TCM and Splice Pack 205. Specifically inspect connector C106, a five terminal connector located below the left side underhood bussed electrical center, directly beneath the red battery cable terminal connection. Perform a mating terminal pull test on all of the terminals in this connector. Repair as required. 4. Observe the Gear Selected screen on the scan tool. The following values should be shown on the Tech 2(R) display and the vehicle's instrument panel cluster (if equipped with the I/P display). ^ "8" (shifter should be in the Park position) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 5082 ^ "7" (shifter should be in the Reverse position) ^ "5" (shifter should be in the Drive position) ^ "3" (shifter should be in the Third gear position) ^ "2" (shifter should be in the Second gear position) ^ "1" (shifter should be in the First gear position) ^ "0" (shifter should be in the Neutral Position) If the Gear Selected display does not match the shifter position in the vehicle, diagnose using one of the following methods. ^ Obtain a new PNP switch kit, P/N 29540479, from the Parts Department. ^ 0.1. Disconnect the wiring connector from the original transmission mounted PNP switch. ^ 0.2. Connect the new switch to the wiring connector. ^ 0.3. Return to Step # 4 above and observe the display as you rotate the switch. If all positions indicate properly, refer to the Correction section below. ^ Use the DTC P0708 diagnostic chart in Service Information (SI) under Transmission/Transaxle/Automatic Transmission - Allison. Reference SI Document ID # 769549 for the wiring schematic for this symptom. The PNP switch, as referenced in SI, is known as the NSBU switch in the Parts information. It is now serviced with a Park Neutral Position Switch Kit, P/N 29540479. Flashing PRNDL Display A flashing PRNDL display may be the result of incorrect sensor inputs or transmission abuse protection modes being received by the TCM. The following are some of these conditions: ^ The transfer case is/was in Neutral. ^ The transfer case is/was shifted into Neutral when the vehicle is moving. ^ A decrease of the input turbine speed was not detected when the gear selector was moved into any gear. ^ A low transmission fluid level. ^ A misadjusted PNP/NSBU switch. ^ Turbine input speed or output speed sensor failure. ^ Failures of the shift solenoids to route the transmission oil to the proper clutch assemblies within the transmission. ^ Failures of the transmission clutch packs (C1 or C5 for first gear, C3 or C5 for Reverse). ^ Failure to detect proper line pressures when a gear range is selected, which may be the result of normal maintenance such as a transmission fluid change having been completed, or the transmission pan was removed for a filter replacement or other type service. Transmission abuse protection modes are encountered when a customer performs one of the following types of maneuvers: ^ Shifting from Neutral to Drive/Reverse when the engine RPM is greater than 1400 RPM. ^ Shifting from Drive to Reverse when the throttle position (TPS) is greater than 25%, such as rocking the vehicle when stuck in an attempt to free the vehicle. ^ When the transmission output speed is greater than 300 RPM from attempted changes in direction such as Reverse to Drive, Drive to Reverse or Neutral to Reverse shifts. When the TCM encounters any one of the above conditions, the TCM will flash the PRNDL and default the transmission to Neutral. A flashing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 5083 PRNDL indicates something is/was incorrect. The transmission may need the attention of a qualified service technician. Correction 1. Disconnect the wiring harness from the PNP switch. 2. Disconnect the shift linkage/cable from the shift lever at the transmission. 3. With a wrench keeping the shift lever from rotating, remove the nut from the end of the selector shaft. 4. Use a file to remove any burrs or raised metal where the selector lever was seated against the shoulder of the selector shaft. Important: If the old PNP switch will not slide from the selector shaft without the effort, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 5. Remove the two bolts that attach the PNP switch and remove the switch by sliding it outward over the selector shaft. 6. Make sure the selector shaft is in the N (neutral) position (using a wrench on the selector shaft flats, rotate the shaft to its furthest clockwise position and then rotate counterclockwise two detents). Important: If the new PNP switch will not slide onto the selector shaft easily, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 7. Slide the new PNP switch over the selector shaft with the neutral assurance bracket 920 facing outward and maintaining the correct PNP switch orientation to the selector shaft. Install and hand tighten the two PNP switch attaching bolts so that the PNP switch and bracket may be rotated within the adjusting slots with some effort. 8. While holding the neutral assurance bracket in engagement with the PNP switch, tighten the two bolts that attach the PNP switch to the transmission case. Tighten Tighten the bolts to 27 N.m (20 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 5084 9. Remove and discard the neutral assurance bracket. Important: Installation of the front shield and rear shields are important. Without proper installation of the shield, a return repair is probable. Follow all directions as listed on the installation instructions sheet included in the Switch kit, P/N 29540479. 10. Fit the new shield onto the PNP switch so that it fits securely against the switch. Make sure this is done before reinstalling the shift lever. 11. Reinstall the shift lever. With a wrench keeping the shift lever from rotating, install the nut on the end of the selector shaft. Tighten. Tighten the nut to 24 N.m (18 lb ft). 12. Connect the wiring harness connectors to the PNP switch. 13. Attach the selector cable to the lever. Check and adjust if needed. 14. Go back to step 4 of the Diagnostics and insure the Tech 2 readings match the shift lever positions. Important: Clear all DTCs before returning the vehicle to the customer. 15. Return the vehicle to the customer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 5085 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Slow/No Gear Engagement/Engine No Start Bulletin No.: 02-07-30-011C Date: June 21, 2004 TECHNICAL Subject: Slow or No Engagement of Automatic Transmission, No Start, Blank PRNDL Display, Flashing PRNDL, DTC P0708, P0872, P0847, P0875, P1711, P1713 or U1000 Set (Diagnose Condition, Repair According to Procedure) Models: 2001-2004 Chevrolet Silverado 2001-2004 GMC Sierra with Allison(R) LCT1000 Automatic Transmission (RPO M74) and 6.6L Duramax(TM) Diesel Engine (RPO LB7) or 8.1L Gas Engine (RPO L18) Supercede: This bulletin is being revised to add model years and additional model information and add graphics. Please discard Corporate Bulletin Number 02-07-30-011B (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions. ^ The PRNDL display is flashing. ^ The engine will not start. ^ The "Service Engine Soon" Indicator lamp is illuminated. ^ The transmission does not shift properly. ^ The vehicle will not move, transmission will not engage. Cause Moisture contamination within the Park Neutral Position (PNP) Switch may cause this condition. This is sometimes referred to as the Neutral Start Back-up (NSBU) Switch. On a left turn, water spray from the left front tire is directed directly at this switch. Proper installation of the "Front Shield" and "Rear Shield" are essential for proper repairs. Technician Diagnosis This bulletin ONLY applies to vehicles equipped with a two connector PNP switch as shown above. A complete and through diagnosis must be performed by a qualified electrical technician to determine the cause and avoid needless replacement of good components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 5091 Important: The Transmission Control Module (TCM) and or the Pressure Switch Manifold (PSM) should NOT be replaced unless properly diagnosed. They are probably not the cause of the concern. It is often assumed the module is the cause of the concern when, in fact, it is another component or the wiring between the components that causes the concern. Important: Remember, everything starts with a properly operating Neutral Start Back Up (NSBU) switch. The NSBU switch has been incorporated into what is now called the Park Neutral Position (PNP) switch. If the PNP switch does not provide the proper voltage signal to the module indicating the transmission is in either Park or Neutral, the module will not allow the starter operation. After the engine is started, and the shift lever is moved to either Reverse or one of the drive positions, the range selected portion of the PNP switch portion provides a voltage input to the module as to what range the driver has manually selected for transmission operation. The module then controls pressures, shift points and other transmission functions based on the voltage input received from the range portion of the PNP switch. The technician may find one or more of the following conditions. The list of these conditions does not imply any type of frequency or order. They are random events and may occur in any order. ^ DTC P0708, Neutral start/backup (PNP or NSBU) switch ^ DTC P0847, Pressure Switch Manifold (PSM) ^ DTC P0872, Pressure Switch Manifold (PSM) ^ DTC P0875, Pressure Switch Manifold (PSM) ^ DTC P1711, Pressure Switch Manifold (PSM) ^ DTC P1713, Pressure Switch Manifold (PSM) ^ DTC U1000, Serial Data Communications ^ Blank PRNDL Display ^ Flashing PRNDL Display ^ Slow or No Engagement of Automatic Transmission Blank PRNDL Display A blank PRNDL display may indicate a condition with the PNP switch and/or one or more of the four signal circuits from the PNP to the TCM. 1. Pin A, Circuit 771 (BLK/WHT) 2. Pin B, Circuit 773 (GRA) 3. Pin C, Circuit 776 (WHT) 4. Pin D, Circuit 772 (YEL) Or, a blank PRNDL display may also occur if an out of line condition exists with the Serial Data Circuit (CKT 2470, yellow wire) from the TCM to Splice Pack 205. Diagnostic Tip 1. Connect the Tech 2(R) to the vehicle. 2. Power up the Tech 2(R). 3. Does the Tech 2(R) communicate with the TCM? If not, inspect the serial data circuit, CKT 2470 (Yellow wire), between the TCM and Splice Pack 205. Specifically inspect connector C106, a five terminal connector located below the left side underhood bussed electrical center, directly beneath the red battery cable terminal connection. Perform a mating terminal pull test on all of the terminals in this connector. Repair as required. 4. Observe the Gear Selected screen on the scan tool. The following values should be shown on the Tech 2(R) display and the vehicle's instrument panel cluster (if equipped with the I/P display). ^ "8" (shifter should be in the Park position) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 5092 ^ "7" (shifter should be in the Reverse position) ^ "5" (shifter should be in the Drive position) ^ "3" (shifter should be in the Third gear position) ^ "2" (shifter should be in the Second gear position) ^ "1" (shifter should be in the First gear position) ^ "0" (shifter should be in the Neutral Position) If the Gear Selected display does not match the shifter position in the vehicle, diagnose using one of the following methods. ^ Obtain a new PNP switch kit, P/N 29540479, from the Parts Department. ^ 0.1. Disconnect the wiring connector from the original transmission mounted PNP switch. ^ 0.2. Connect the new switch to the wiring connector. ^ 0.3. Return to Step # 4 above and observe the display as you rotate the switch. If all positions indicate properly, refer to the Correction section below. ^ Use the DTC P0708 diagnostic chart in Service Information (SI) under Transmission/Transaxle/Automatic Transmission - Allison. Reference SI Document ID # 769549 for the wiring schematic for this symptom. The PNP switch, as referenced in SI, is known as the NSBU switch in the Parts information. It is now serviced with a Park Neutral Position Switch Kit, P/N 29540479. Flashing PRNDL Display A flashing PRNDL display may be the result of incorrect sensor inputs or transmission abuse protection modes being received by the TCM. The following are some of these conditions: ^ The transfer case is/was in Neutral. ^ The transfer case is/was shifted into Neutral when the vehicle is moving. ^ A decrease of the input turbine speed was not detected when the gear selector was moved into any gear. ^ A low transmission fluid level. ^ A misadjusted PNP/NSBU switch. ^ Turbine input speed or output speed sensor failure. ^ Failures of the shift solenoids to route the transmission oil to the proper clutch assemblies within the transmission. ^ Failures of the transmission clutch packs (C1 or C5 for first gear, C3 or C5 for Reverse). ^ Failure to detect proper line pressures when a gear range is selected, which may be the result of normal maintenance such as a transmission fluid change having been completed, or the transmission pan was removed for a filter replacement or other type service. Transmission abuse protection modes are encountered when a customer performs one of the following types of maneuvers: ^ Shifting from Neutral to Drive/Reverse when the engine RPM is greater than 1400 RPM. ^ Shifting from Drive to Reverse when the throttle position (TPS) is greater than 25%, such as rocking the vehicle when stuck in an attempt to free the vehicle. ^ When the transmission output speed is greater than 300 RPM from attempted changes in direction such as Reverse to Drive, Drive to Reverse or Neutral to Reverse shifts. When the TCM encounters any one of the above conditions, the TCM will flash the PRNDL and default the transmission to Neutral. A flashing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 5093 PRNDL indicates something is/was incorrect. The transmission may need the attention of a qualified service technician. Correction 1. Disconnect the wiring harness from the PNP switch. 2. Disconnect the shift linkage/cable from the shift lever at the transmission. 3. With a wrench keeping the shift lever from rotating, remove the nut from the end of the selector shaft. 4. Use a file to remove any burrs or raised metal where the selector lever was seated against the shoulder of the selector shaft. Important: If the old PNP switch will not slide from the selector shaft without the effort, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 5. Remove the two bolts that attach the PNP switch and remove the switch by sliding it outward over the selector shaft. 6. Make sure the selector shaft is in the N (neutral) position (using a wrench on the selector shaft flats, rotate the shaft to its furthest clockwise position and then rotate counterclockwise two detents). Important: If the new PNP switch will not slide onto the selector shaft easily, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 7. Slide the new PNP switch over the selector shaft with the neutral assurance bracket 920 facing outward and maintaining the correct PNP switch orientation to the selector shaft. Install and hand tighten the two PNP switch attaching bolts so that the PNP switch and bracket may be rotated within the adjusting slots with some effort. 8. While holding the neutral assurance bracket in engagement with the PNP switch, tighten the two bolts that attach the PNP switch to the transmission case. Tighten Tighten the bolts to 27 N.m (20 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 5094 9. Remove and discard the neutral assurance bracket. Important: Installation of the front shield and rear shields are important. Without proper installation of the shield, a return repair is probable. Follow all directions as listed on the installation instructions sheet included in the Switch kit, P/N 29540479. 10. Fit the new shield onto the PNP switch so that it fits securely against the switch. Make sure this is done before reinstalling the shift lever. 11. Reinstall the shift lever. With a wrench keeping the shift lever from rotating, install the nut on the end of the selector shaft. Tighten. Tighten the nut to 24 N.m (18 lb ft). 12. Connect the wiring harness connectors to the PNP switch. 13. Attach the selector cable to the lever. Check and adjust if needed. 14. Go back to step 4 of the Diagnostics and insure the Tech 2 readings match the shift lever positions. Important: Clear all DTCs before returning the vehicle to the customer. 15. Return the vehicle to the customer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 5095 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 00-07-30-022D > Jun > 08 > A/T 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: All Technical Service Bulletins A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 00-07-30-022D > Jun > 08 > A/T 4L60/65E, No Reverse/2nd or 4th Gear > Page 5101 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 00-07-30-022D > Jun > 08 > A/T 4L60/65E, No Reverse/2nd or 4th Gear > Page 5102 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 00-07-30-022D > Jun > 08 > A/T 4L60/65E, No Reverse/2nd or 4th Gear > Page 5108 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 00-07-30-022D > Jun > 08 > A/T 4L60/65E, No Reverse/2nd or 4th Gear > Page 5109 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 5110 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 5111 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 5114 Transmission Position Switch/Sensor: Adjustments Automatic Transmission - Allison Park/Neutral Position Switch Adjustment ^ Tools Required J 41364-A PNP Switch Adjusting Tool Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Make sure the selector shaft is in the N (Neutral) position as follows: ^ Place a wrench on the selector shaft flats and rotate the shaft to its furthest clockwise position. ^ Rotate the selector shaft counter-clockwise two detents. 2. Be sure that J 41364-A (2) is in the proper position on PNP switch (1). 3. While maintaining the correct PNP switch-to-selector-shaft alignment, slide the new PNP switch (5) over the selector shaft (4). 4. Notice: Refer to Component Fastener Tightening Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 5115 While holding J 41364-A in engagement with the PNP switch, install the two bolts (6) so that the PNP switch may be rotated with some effort. ^ Tighten the two bolts (6) to 27 Nm (20 ft. lbs.). 5. Remove J 41364-A. 6. Install splash shield (1), concave side toward PNP switch (3), over selector shaft (2). 7. Notice: Refer to Transmission Selector Shaft Abuse Notice in Service Precautions. Reinstall Shift Lever (2). Install nut (3), by hand, on the end of selector shaft (4). Use a wrench (1) to keep the shift lever from rotating. ^ Tighten nut (3) to 24 Nm (18 ft. lbs.) 8. Reconnect the shift selector linkage/cable to the shift lever (2). 9. Connect the external wiring harness to the PNP switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L80-E/4L85-E Park/Neutral Position Switch Replacement Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 5118 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 5119 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 5120 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Park Lock Pawl and Actuator Replacement Park Lock Pawl and Actuator Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the park/neutral position (PNP) switch. 3. Remove the manual shaft nut and pin. 4. Remove the detent lever and actuator. 5. Remove the parking pawl bracket bolts. 6. Remove the parking pawl return spring. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 5121 7. Use the modified screw extractor in order to remove the plug. 8. Remove the parking pawl shaft retainer, shaft and pawl. 9. Important: If the manual shaft binds in the case during removal, file or sand the shaft in the area adjacent to the detent lever. Remove the manual shaft. 10. Remove the manual shaft seal. Installation Procedure 1. Install the pawl shaft. 2. Install the parking pawl. 3. Install the plug using a 8 mm or (5/16 inch) rod with Loctite® or equivalent. 4. Install the retainer. 5. Install the pawl return spring. 6. Install the detent lever to the actuator. 7. Install the actuator over the parking pawl. 8. Install the manual shaft seal. 9. Lubricate the manual shaft with transmission oil and install the manual shaft into the case. 10. Install the nut on the shaft. 11. Install the roll pin. 12. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 5122 Install the parking lock bracket bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 13. Install the PNP switch. 14. Install the transmission filter. 15. Fill the transmission to the proper level with Dexron® III transmission fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 5123 Transmission Position Switch/Sensor: Service and Repair Automatic Transmission - Allison Park/Neutral Position Switch Replacement PNP Switch Removal Refer to Park/Neutral Position Switch Removal. PNP Switch Install Refer to Park/Neutral Position Switch Installation. 7. Notice: Refer to Transmission Selector Shaft Abuse Notice in Service Precautions. Reinstall shift lever (2). Install nut (3), by hand, on the end of selector shaft (4). Use a wrench (1) to keep the shift lever from rotating. ^ Tighten nut (3) to 24 Nm (18 ft. lbs.). 8. Reconnect the shift selector linkage/cable to the shift lever (2). 9. Connect the external wiring harness to the PNP switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > A/T Shifting/Poor Performance Vehicle Speed Sensor: Technical Service Bulletins A/T - Shifting/Poor Performance INFORMATION Bulletin No.: 01-03-10-010G Date: July 22, 2009 Subject: Inspection of Tire and Wheel Size Prior to Diagnosis of Transmission Shifts, Poor Performance, Speedometer, Cruise Control Concerns Models: 2001-2007 Chevrolet Silverado Pickup (Classic) Models Equipped with Allison(R) Automatic Transmission Only 2001-2007 GMC Sierra Pickup (Classic) Models Equipped with Allison(R) Automatic Transmission Only 2007-2010 Chevrolet Silverado Pickup HD Models 2007-2010 GMC Sierra Pickup HD Models Supercede: This bulletin is being revised to add the 2008-2010 model years, update the tire size information and reference the vehicle tire information label locations. Please discard Corporate Bulletin Number 01-03-10-010F (Section 03 - Suspension). GM has developed and matched specific tires for your vehicle. The original equipment tires and their respective size installed on the vehicle when it was new, were designed to meet General Motors Tire Performance Criteria Specification (TPC Spec) system rating. GM's exclusive TPC Spec system considers over a dozen critical specifications that impact the overall performance of the vehicle. A truck that has different tires and wheels from the original equipment designed for that vehicle will have engine power/performance concerns, transmission shift concerns, speedometer registered speed concerns, cruise control concerns and increased steering effort, especially during parking lot maneuvers at slow speeds. The engine control module (ECM) and transmission control module (TCM) use engine speed (RPM) and vehicle speed sensor (VSS) inputs as operational parameters for engine torque, transmission shifting, cruise control operation and speedometer indicated vehicle speed. Calibrations for different tire/wheel combinations are not available. Therefore, changing of tire and/or wheel size should not be undertaken by dealerships or truck owners. Proper diagnosis of engine, transmission, speedometer and cruise control concerns MUST begin with an inspection of tire/wheel size. Important A vehicle specific Tire and Loading Information label is attached to the center pillar (B-pillar) of the vehicle. With the driver's door open, you will find the label attached below the door lock post (striker). The label shows the size of the original equipment tires and the recommended cold tire inflation pressures.A vehicle specific Certification/Tire label is found on the rear edge of the driver's door. The label shows the size of the original equipment tires and the recommended cold tire inflation pressures. 2001-2007 Pickups (Classic) Equipped with Allison(R) Automatic Transmission Only Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT215/85R16D tires as standard equipment. 2007 Pickups HD Models (New Design Pickups) Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT215/85R16E tires as standard equipment. 2008-2010 Pickups HD Models (New Design Pickups) Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > A/T Shifting/Poor Performance > Page 5128 - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT225/75R17E tires as standard equipment. If a truck is found to have other than the above listed tire sizes, no further diagnosis should be undertaken until the original size tires and wheels are reinstalled on the truck. Warranty Information Reinstalling the proper wheels and tires on the vehicle, prior to performing any type of diagnosis of the truck, would be considered truck owner responsibility and not a warranty repair. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Vehicle Speed Sensor (VSS) Vehicle Speed Sensor: Diagrams Vehicle Speed Sensor (VSS) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Vehicle Speed Sensor (VSS) > Page 5131 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Vehicle Speed Sensor (VSS) > Page 5132 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 Vehicle Speed Sensor: Service and Repair Manual Transmission - NV 3500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 5135 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and O-ring seal. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 5136 Vehicle Speed Sensor: Service and Repair Manual Transmission - NV 4500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (3). 3. Remove the VSS and seal. Installation Procedure 1. Coat the NEW O-ring seal with a thin film of transmission fluid, use GM P/N 12346190 (Canadian P/N 10953477), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 5137 3. Connect the VSS electrical connector (3). Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 5138 Vehicle Speed Sensor: Service and Repair Manual Transmission - ZF S6-650 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped with the 6.6L engine, disconnect the vehicle speed sensor (VSS) electrical connector (4). 3. If equipped with the 8.1L engine, disconnect the VSS electrical connector (5). 4. Remove the VSS bolt, sensor and seal. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 5139 1. Lubricate a NEW O-ring seal with transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). 3. If equipped with the 8.1L engine, connect the VSS electrical connector (5). 4. If equipped with the 6.6L engine, connect the VSS electrical connector (4). 5. Lower the vehicle. 6. Check the transmission fluid level. Add if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 5140 Vehicle Speed Sensor: Service and Repair Automatic Transmission - 4L60-E/4L65-E Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). 4. Notice: Refer to Fastener Notice in Service Precautions. Install the VSS bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 5141 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start Transmission Position Switch/Sensor: Customer Interest A/T - Slow/No Gear Engagement/Engine No Start Bulletin No.: 02-07-30-011C Date: June 21, 2004 TECHNICAL Subject: Slow or No Engagement of Automatic Transmission, No Start, Blank PRNDL Display, Flashing PRNDL, DTC P0708, P0872, P0847, P0875, P1711, P1713 or U1000 Set (Diagnose Condition, Repair According to Procedure) Models: 2001-2004 Chevrolet Silverado 2001-2004 GMC Sierra with Allison(R) LCT1000 Automatic Transmission (RPO M74) and 6.6L Duramax(TM) Diesel Engine (RPO LB7) or 8.1L Gas Engine (RPO L18) Supercede: This bulletin is being revised to add model years and additional model information and add graphics. Please discard Corporate Bulletin Number 02-07-30-011B (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions. ^ The PRNDL display is flashing. ^ The engine will not start. ^ The "Service Engine Soon" Indicator lamp is illuminated. ^ The transmission does not shift properly. ^ The vehicle will not move, transmission will not engage. Cause Moisture contamination within the Park Neutral Position (PNP) Switch may cause this condition. This is sometimes referred to as the Neutral Start Back-up (NSBU) Switch. On a left turn, water spray from the left front tire is directed directly at this switch. Proper installation of the "Front Shield" and "Rear Shield" are essential for proper repairs. Technician Diagnosis This bulletin ONLY applies to vehicles equipped with a two connector PNP switch as shown above. A complete and through diagnosis must be performed by a qualified electrical technician to determine the cause and avoid needless replacement of good components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 5150 Important: The Transmission Control Module (TCM) and or the Pressure Switch Manifold (PSM) should NOT be replaced unless properly diagnosed. They are probably not the cause of the concern. It is often assumed the module is the cause of the concern when, in fact, it is another component or the wiring between the components that causes the concern. Important: Remember, everything starts with a properly operating Neutral Start Back Up (NSBU) switch. The NSBU switch has been incorporated into what is now called the Park Neutral Position (PNP) switch. If the PNP switch does not provide the proper voltage signal to the module indicating the transmission is in either Park or Neutral, the module will not allow the starter operation. After the engine is started, and the shift lever is moved to either Reverse or one of the drive positions, the range selected portion of the PNP switch portion provides a voltage input to the module as to what range the driver has manually selected for transmission operation. The module then controls pressures, shift points and other transmission functions based on the voltage input received from the range portion of the PNP switch. The technician may find one or more of the following conditions. The list of these conditions does not imply any type of frequency or order. They are random events and may occur in any order. ^ DTC P0708, Neutral start/backup (PNP or NSBU) switch ^ DTC P0847, Pressure Switch Manifold (PSM) ^ DTC P0872, Pressure Switch Manifold (PSM) ^ DTC P0875, Pressure Switch Manifold (PSM) ^ DTC P1711, Pressure Switch Manifold (PSM) ^ DTC P1713, Pressure Switch Manifold (PSM) ^ DTC U1000, Serial Data Communications ^ Blank PRNDL Display ^ Flashing PRNDL Display ^ Slow or No Engagement of Automatic Transmission Blank PRNDL Display A blank PRNDL display may indicate a condition with the PNP switch and/or one or more of the four signal circuits from the PNP to the TCM. 1. Pin A, Circuit 771 (BLK/WHT) 2. Pin B, Circuit 773 (GRA) 3. Pin C, Circuit 776 (WHT) 4. Pin D, Circuit 772 (YEL) Or, a blank PRNDL display may also occur if an out of line condition exists with the Serial Data Circuit (CKT 2470, yellow wire) from the TCM to Splice Pack 205. Diagnostic Tip 1. Connect the Tech 2(R) to the vehicle. 2. Power up the Tech 2(R). 3. Does the Tech 2(R) communicate with the TCM? If not, inspect the serial data circuit, CKT 2470 (Yellow wire), between the TCM and Splice Pack 205. Specifically inspect connector C106, a five terminal connector located below the left side underhood bussed electrical center, directly beneath the red battery cable terminal connection. Perform a mating terminal pull test on all of the terminals in this connector. Repair as required. 4. Observe the Gear Selected screen on the scan tool. The following values should be shown on the Tech 2(R) display and the vehicle's instrument panel cluster (if equipped with the I/P display). ^ "8" (shifter should be in the Park position) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 5151 ^ "7" (shifter should be in the Reverse position) ^ "5" (shifter should be in the Drive position) ^ "3" (shifter should be in the Third gear position) ^ "2" (shifter should be in the Second gear position) ^ "1" (shifter should be in the First gear position) ^ "0" (shifter should be in the Neutral Position) If the Gear Selected display does not match the shifter position in the vehicle, diagnose using one of the following methods. ^ Obtain a new PNP switch kit, P/N 29540479, from the Parts Department. ^ 0.1. Disconnect the wiring connector from the original transmission mounted PNP switch. ^ 0.2. Connect the new switch to the wiring connector. ^ 0.3. Return to Step # 4 above and observe the display as you rotate the switch. If all positions indicate properly, refer to the Correction section below. ^ Use the DTC P0708 diagnostic chart in Service Information (SI) under Transmission/Transaxle/Automatic Transmission - Allison. Reference SI Document ID # 769549 for the wiring schematic for this symptom. The PNP switch, as referenced in SI, is known as the NSBU switch in the Parts information. It is now serviced with a Park Neutral Position Switch Kit, P/N 29540479. Flashing PRNDL Display A flashing PRNDL display may be the result of incorrect sensor inputs or transmission abuse protection modes being received by the TCM. The following are some of these conditions: ^ The transfer case is/was in Neutral. ^ The transfer case is/was shifted into Neutral when the vehicle is moving. ^ A decrease of the input turbine speed was not detected when the gear selector was moved into any gear. ^ A low transmission fluid level. ^ A misadjusted PNP/NSBU switch. ^ Turbine input speed or output speed sensor failure. ^ Failures of the shift solenoids to route the transmission oil to the proper clutch assemblies within the transmission. ^ Failures of the transmission clutch packs (C1 or C5 for first gear, C3 or C5 for Reverse). ^ Failure to detect proper line pressures when a gear range is selected, which may be the result of normal maintenance such as a transmission fluid change having been completed, or the transmission pan was removed for a filter replacement or other type service. Transmission abuse protection modes are encountered when a customer performs one of the following types of maneuvers: ^ Shifting from Neutral to Drive/Reverse when the engine RPM is greater than 1400 RPM. ^ Shifting from Drive to Reverse when the throttle position (TPS) is greater than 25%, such as rocking the vehicle when stuck in an attempt to free the vehicle. ^ When the transmission output speed is greater than 300 RPM from attempted changes in direction such as Reverse to Drive, Drive to Reverse or Neutral to Reverse shifts. When the TCM encounters any one of the above conditions, the TCM will flash the PRNDL and default the transmission to Neutral. A flashing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 5152 PRNDL indicates something is/was incorrect. The transmission may need the attention of a qualified service technician. Correction 1. Disconnect the wiring harness from the PNP switch. 2. Disconnect the shift linkage/cable from the shift lever at the transmission. 3. With a wrench keeping the shift lever from rotating, remove the nut from the end of the selector shaft. 4. Use a file to remove any burrs or raised metal where the selector lever was seated against the shoulder of the selector shaft. Important: If the old PNP switch will not slide from the selector shaft without the effort, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 5. Remove the two bolts that attach the PNP switch and remove the switch by sliding it outward over the selector shaft. 6. Make sure the selector shaft is in the N (neutral) position (using a wrench on the selector shaft flats, rotate the shaft to its furthest clockwise position and then rotate counterclockwise two detents). Important: If the new PNP switch will not slide onto the selector shaft easily, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 7. Slide the new PNP switch over the selector shaft with the neutral assurance bracket 920 facing outward and maintaining the correct PNP switch orientation to the selector shaft. Install and hand tighten the two PNP switch attaching bolts so that the PNP switch and bracket may be rotated within the adjusting slots with some effort. 8. While holding the neutral assurance bracket in engagement with the PNP switch, tighten the two bolts that attach the PNP switch to the transmission case. Tighten Tighten the bolts to 27 N.m (20 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 5153 9. Remove and discard the neutral assurance bracket. Important: Installation of the front shield and rear shields are important. Without proper installation of the shield, a return repair is probable. Follow all directions as listed on the installation instructions sheet included in the Switch kit, P/N 29540479. 10. Fit the new shield onto the PNP switch so that it fits securely against the switch. Make sure this is done before reinstalling the shift lever. 11. Reinstall the shift lever. With a wrench keeping the shift lever from rotating, install the nut on the end of the selector shaft. Tighten. Tighten the nut to 24 N.m (18 lb ft). 12. Connect the wiring harness connectors to the PNP switch. 13. Attach the selector cable to the lever. Check and adjust if needed. 14. Go back to step 4 of the Diagnostics and insure the Tech 2 readings match the shift lever positions. Important: Clear all DTCs before returning the vehicle to the customer. 15. Return the vehicle to the customer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 5154 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Slow/No Gear Engagement/Engine No Start Bulletin No.: 02-07-30-011C Date: June 21, 2004 TECHNICAL Subject: Slow or No Engagement of Automatic Transmission, No Start, Blank PRNDL Display, Flashing PRNDL, DTC P0708, P0872, P0847, P0875, P1711, P1713 or U1000 Set (Diagnose Condition, Repair According to Procedure) Models: 2001-2004 Chevrolet Silverado 2001-2004 GMC Sierra with Allison(R) LCT1000 Automatic Transmission (RPO M74) and 6.6L Duramax(TM) Diesel Engine (RPO LB7) or 8.1L Gas Engine (RPO L18) Supercede: This bulletin is being revised to add model years and additional model information and add graphics. Please discard Corporate Bulletin Number 02-07-30-011B (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions. ^ The PRNDL display is flashing. ^ The engine will not start. ^ The "Service Engine Soon" Indicator lamp is illuminated. ^ The transmission does not shift properly. ^ The vehicle will not move, transmission will not engage. Cause Moisture contamination within the Park Neutral Position (PNP) Switch may cause this condition. This is sometimes referred to as the Neutral Start Back-up (NSBU) Switch. On a left turn, water spray from the left front tire is directed directly at this switch. Proper installation of the "Front Shield" and "Rear Shield" are essential for proper repairs. Technician Diagnosis This bulletin ONLY applies to vehicles equipped with a two connector PNP switch as shown above. A complete and through diagnosis must be performed by a qualified electrical technician to determine the cause and avoid needless replacement of good components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 5160 Important: The Transmission Control Module (TCM) and or the Pressure Switch Manifold (PSM) should NOT be replaced unless properly diagnosed. They are probably not the cause of the concern. It is often assumed the module is the cause of the concern when, in fact, it is another component or the wiring between the components that causes the concern. Important: Remember, everything starts with a properly operating Neutral Start Back Up (NSBU) switch. The NSBU switch has been incorporated into what is now called the Park Neutral Position (PNP) switch. If the PNP switch does not provide the proper voltage signal to the module indicating the transmission is in either Park or Neutral, the module will not allow the starter operation. After the engine is started, and the shift lever is moved to either Reverse or one of the drive positions, the range selected portion of the PNP switch portion provides a voltage input to the module as to what range the driver has manually selected for transmission operation. The module then controls pressures, shift points and other transmission functions based on the voltage input received from the range portion of the PNP switch. The technician may find one or more of the following conditions. The list of these conditions does not imply any type of frequency or order. They are random events and may occur in any order. ^ DTC P0708, Neutral start/backup (PNP or NSBU) switch ^ DTC P0847, Pressure Switch Manifold (PSM) ^ DTC P0872, Pressure Switch Manifold (PSM) ^ DTC P0875, Pressure Switch Manifold (PSM) ^ DTC P1711, Pressure Switch Manifold (PSM) ^ DTC P1713, Pressure Switch Manifold (PSM) ^ DTC U1000, Serial Data Communications ^ Blank PRNDL Display ^ Flashing PRNDL Display ^ Slow or No Engagement of Automatic Transmission Blank PRNDL Display A blank PRNDL display may indicate a condition with the PNP switch and/or one or more of the four signal circuits from the PNP to the TCM. 1. Pin A, Circuit 771 (BLK/WHT) 2. Pin B, Circuit 773 (GRA) 3. Pin C, Circuit 776 (WHT) 4. Pin D, Circuit 772 (YEL) Or, a blank PRNDL display may also occur if an out of line condition exists with the Serial Data Circuit (CKT 2470, yellow wire) from the TCM to Splice Pack 205. Diagnostic Tip 1. Connect the Tech 2(R) to the vehicle. 2. Power up the Tech 2(R). 3. Does the Tech 2(R) communicate with the TCM? If not, inspect the serial data circuit, CKT 2470 (Yellow wire), between the TCM and Splice Pack 205. Specifically inspect connector C106, a five terminal connector located below the left side underhood bussed electrical center, directly beneath the red battery cable terminal connection. Perform a mating terminal pull test on all of the terminals in this connector. Repair as required. 4. Observe the Gear Selected screen on the scan tool. The following values should be shown on the Tech 2(R) display and the vehicle's instrument panel cluster (if equipped with the I/P display). ^ "8" (shifter should be in the Park position) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 5161 ^ "7" (shifter should be in the Reverse position) ^ "5" (shifter should be in the Drive position) ^ "3" (shifter should be in the Third gear position) ^ "2" (shifter should be in the Second gear position) ^ "1" (shifter should be in the First gear position) ^ "0" (shifter should be in the Neutral Position) If the Gear Selected display does not match the shifter position in the vehicle, diagnose using one of the following methods. ^ Obtain a new PNP switch kit, P/N 29540479, from the Parts Department. ^ 0.1. Disconnect the wiring connector from the original transmission mounted PNP switch. ^ 0.2. Connect the new switch to the wiring connector. ^ 0.3. Return to Step # 4 above and observe the display as you rotate the switch. If all positions indicate properly, refer to the Correction section below. ^ Use the DTC P0708 diagnostic chart in Service Information (SI) under Transmission/Transaxle/Automatic Transmission - Allison. Reference SI Document ID # 769549 for the wiring schematic for this symptom. The PNP switch, as referenced in SI, is known as the NSBU switch in the Parts information. It is now serviced with a Park Neutral Position Switch Kit, P/N 29540479. Flashing PRNDL Display A flashing PRNDL display may be the result of incorrect sensor inputs or transmission abuse protection modes being received by the TCM. The following are some of these conditions: ^ The transfer case is/was in Neutral. ^ The transfer case is/was shifted into Neutral when the vehicle is moving. ^ A decrease of the input turbine speed was not detected when the gear selector was moved into any gear. ^ A low transmission fluid level. ^ A misadjusted PNP/NSBU switch. ^ Turbine input speed or output speed sensor failure. ^ Failures of the shift solenoids to route the transmission oil to the proper clutch assemblies within the transmission. ^ Failures of the transmission clutch packs (C1 or C5 for first gear, C3 or C5 for Reverse). ^ Failure to detect proper line pressures when a gear range is selected, which may be the result of normal maintenance such as a transmission fluid change having been completed, or the transmission pan was removed for a filter replacement or other type service. Transmission abuse protection modes are encountered when a customer performs one of the following types of maneuvers: ^ Shifting from Neutral to Drive/Reverse when the engine RPM is greater than 1400 RPM. ^ Shifting from Drive to Reverse when the throttle position (TPS) is greater than 25%, such as rocking the vehicle when stuck in an attempt to free the vehicle. ^ When the transmission output speed is greater than 300 RPM from attempted changes in direction such as Reverse to Drive, Drive to Reverse or Neutral to Reverse shifts. When the TCM encounters any one of the above conditions, the TCM will flash the PRNDL and default the transmission to Neutral. A flashing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 5162 PRNDL indicates something is/was incorrect. The transmission may need the attention of a qualified service technician. Correction 1. Disconnect the wiring harness from the PNP switch. 2. Disconnect the shift linkage/cable from the shift lever at the transmission. 3. With a wrench keeping the shift lever from rotating, remove the nut from the end of the selector shaft. 4. Use a file to remove any burrs or raised metal where the selector lever was seated against the shoulder of the selector shaft. Important: If the old PNP switch will not slide from the selector shaft without the effort, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 5. Remove the two bolts that attach the PNP switch and remove the switch by sliding it outward over the selector shaft. 6. Make sure the selector shaft is in the N (neutral) position (using a wrench on the selector shaft flats, rotate the shaft to its furthest clockwise position and then rotate counterclockwise two detents). Important: If the new PNP switch will not slide onto the selector shaft easily, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 7. Slide the new PNP switch over the selector shaft with the neutral assurance bracket 920 facing outward and maintaining the correct PNP switch orientation to the selector shaft. Install and hand tighten the two PNP switch attaching bolts so that the PNP switch and bracket may be rotated within the adjusting slots with some effort. 8. While holding the neutral assurance bracket in engagement with the PNP switch, tighten the two bolts that attach the PNP switch to the transmission case. Tighten Tighten the bolts to 27 N.m (20 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 5163 9. Remove and discard the neutral assurance bracket. Important: Installation of the front shield and rear shields are important. Without proper installation of the shield, a return repair is probable. Follow all directions as listed on the installation instructions sheet included in the Switch kit, P/N 29540479. 10. Fit the new shield onto the PNP switch so that it fits securely against the switch. Make sure this is done before reinstalling the shift lever. 11. Reinstall the shift lever. With a wrench keeping the shift lever from rotating, install the nut on the end of the selector shaft. Tighten. Tighten the nut to 24 N.m (18 lb ft). 12. Connect the wiring harness connectors to the PNP switch. 13. Attach the selector cable to the lever. Check and adjust if needed. 14. Go back to step 4 of the Diagnostics and insure the Tech 2 readings match the shift lever positions. Important: Clear all DTCs before returning the vehicle to the customer. 15. Return the vehicle to the customer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 5164 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 5165 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 5166 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 5169 Transmission Position Switch/Sensor: Adjustments Automatic Transmission - Allison Park/Neutral Position Switch Adjustment ^ Tools Required J 41364-A PNP Switch Adjusting Tool Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Make sure the selector shaft is in the N (Neutral) position as follows: ^ Place a wrench on the selector shaft flats and rotate the shaft to its furthest clockwise position. ^ Rotate the selector shaft counter-clockwise two detents. 2. Be sure that J 41364-A (2) is in the proper position on PNP switch (1). 3. While maintaining the correct PNP switch-to-selector-shaft alignment, slide the new PNP switch (5) over the selector shaft (4). 4. Notice: Refer to Component Fastener Tightening Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 5170 While holding J 41364-A in engagement with the PNP switch, install the two bolts (6) so that the PNP switch may be rotated with some effort. ^ Tighten the two bolts (6) to 27 Nm (20 ft. lbs.). 5. Remove J 41364-A. 6. Install splash shield (1), concave side toward PNP switch (3), over selector shaft (2). 7. Notice: Refer to Transmission Selector Shaft Abuse Notice in Service Precautions. Reinstall Shift Lever (2). Install nut (3), by hand, on the end of selector shaft (4). Use a wrench (1) to keep the shift lever from rotating. ^ Tighten nut (3) to 24 Nm (18 ft. lbs.) 8. Reconnect the shift selector linkage/cable to the shift lever (2). 9. Connect the external wiring harness to the PNP switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L80-E/4L85-E Park/Neutral Position Switch Replacement Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 5173 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 5174 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 5175 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Park Lock Pawl and Actuator Replacement Park Lock Pawl and Actuator Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the park/neutral position (PNP) switch. 3. Remove the manual shaft nut and pin. 4. Remove the detent lever and actuator. 5. Remove the parking pawl bracket bolts. 6. Remove the parking pawl return spring. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 5176 7. Use the modified screw extractor in order to remove the plug. 8. Remove the parking pawl shaft retainer, shaft and pawl. 9. Important: If the manual shaft binds in the case during removal, file or sand the shaft in the area adjacent to the detent lever. Remove the manual shaft. 10. Remove the manual shaft seal. Installation Procedure 1. Install the pawl shaft. 2. Install the parking pawl. 3. Install the plug using a 8 mm or (5/16 inch) rod with Loctite® or equivalent. 4. Install the retainer. 5. Install the pawl return spring. 6. Install the detent lever to the actuator. 7. Install the actuator over the parking pawl. 8. Install the manual shaft seal. 9. Lubricate the manual shaft with transmission oil and install the manual shaft into the case. 10. Install the nut on the shaft. 11. Install the roll pin. 12. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 5177 Install the parking lock bracket bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 13. Install the PNP switch. 14. Install the transmission filter. 15. Fill the transmission to the proper level with Dexron® III transmission fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 5178 Transmission Position Switch/Sensor: Service and Repair Automatic Transmission - Allison Park/Neutral Position Switch Replacement PNP Switch Removal Refer to Park/Neutral Position Switch Removal. PNP Switch Install Refer to Park/Neutral Position Switch Installation. 7. Notice: Refer to Transmission Selector Shaft Abuse Notice in Service Precautions. Reinstall shift lever (2). Install nut (3), by hand, on the end of selector shaft (4). Use a wrench (1) to keep the shift lever from rotating. ^ Tighten nut (3) to 24 Nm (18 ft. lbs.). 8. Reconnect the shift selector linkage/cable to the shift lever (2). 9. Connect the external wiring harness to the PNP switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > A/T - Shifting/Poor Performance Vehicle Speed Sensor: Technical Service Bulletins A/T - Shifting/Poor Performance INFORMATION Bulletin No.: 01-03-10-010G Date: July 22, 2009 Subject: Inspection of Tire and Wheel Size Prior to Diagnosis of Transmission Shifts, Poor Performance, Speedometer, Cruise Control Concerns Models: 2001-2007 Chevrolet Silverado Pickup (Classic) Models Equipped with Allison(R) Automatic Transmission Only 2001-2007 GMC Sierra Pickup (Classic) Models Equipped with Allison(R) Automatic Transmission Only 2007-2010 Chevrolet Silverado Pickup HD Models 2007-2010 GMC Sierra Pickup HD Models Supercede: This bulletin is being revised to add the 2008-2010 model years, update the tire size information and reference the vehicle tire information label locations. Please discard Corporate Bulletin Number 01-03-10-010F (Section 03 - Suspension). GM has developed and matched specific tires for your vehicle. The original equipment tires and their respective size installed on the vehicle when it was new, were designed to meet General Motors Tire Performance Criteria Specification (TPC Spec) system rating. GM's exclusive TPC Spec system considers over a dozen critical specifications that impact the overall performance of the vehicle. A truck that has different tires and wheels from the original equipment designed for that vehicle will have engine power/performance concerns, transmission shift concerns, speedometer registered speed concerns, cruise control concerns and increased steering effort, especially during parking lot maneuvers at slow speeds. The engine control module (ECM) and transmission control module (TCM) use engine speed (RPM) and vehicle speed sensor (VSS) inputs as operational parameters for engine torque, transmission shifting, cruise control operation and speedometer indicated vehicle speed. Calibrations for different tire/wheel combinations are not available. Therefore, changing of tire and/or wheel size should not be undertaken by dealerships or truck owners. Proper diagnosis of engine, transmission, speedometer and cruise control concerns MUST begin with an inspection of tire/wheel size. Important A vehicle specific Tire and Loading Information label is attached to the center pillar (B-pillar) of the vehicle. With the driver's door open, you will find the label attached below the door lock post (striker). The label shows the size of the original equipment tires and the recommended cold tire inflation pressures.A vehicle specific Certification/Tire label is found on the rear edge of the driver's door. The label shows the size of the original equipment tires and the recommended cold tire inflation pressures. 2001-2007 Pickups (Classic) Equipped with Allison(R) Automatic Transmission Only Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT215/85R16D tires as standard equipment. 2007 Pickups HD Models (New Design Pickups) Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT215/85R16E tires as standard equipment. 2008-2010 Pickups HD Models (New Design Pickups) Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > A/T - Shifting/Poor Performance > Page 5183 - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT225/75R17E tires as standard equipment. If a truck is found to have other than the above listed tire sizes, no further diagnosis should be undertaken until the original size tires and wheels are reinstalled on the truck. Warranty Information Reinstalling the proper wheels and tires on the vehicle, prior to performing any type of diagnosis of the truck, would be considered truck owner responsibility and not a warranty repair. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Vehicle Speed Sensor (VSS) Vehicle Speed Sensor: Diagrams Vehicle Speed Sensor (VSS) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Vehicle Speed Sensor (VSS) > Page 5186 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Vehicle Speed Sensor (VSS) > Page 5187 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 Vehicle Speed Sensor: Service and Repair Manual Transmission - NV 3500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 5190 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and O-ring seal. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 5191 Vehicle Speed Sensor: Service and Repair Manual Transmission - NV 4500 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (3). 3. Remove the VSS and seal. Installation Procedure 1. Coat the NEW O-ring seal with a thin film of transmission fluid, use GM P/N 12346190 (Canadian P/N 10953477), or equivalent. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS. ^ Tighten the VSS to 16 Nm (12 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 5192 3. Connect the VSS electrical connector (3). Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 5193 Vehicle Speed Sensor: Service and Repair Manual Transmission - ZF S6-650 Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped with the 6.6L engine, disconnect the vehicle speed sensor (VSS) electrical connector (4). 3. If equipped with the 8.1L engine, disconnect the VSS electrical connector (5). 4. Remove the VSS bolt, sensor and seal. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 5194 1. Lubricate a NEW O-ring seal with transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the VSS and bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). 3. If equipped with the 8.1L engine, connect the VSS electrical connector (5). 4. If equipped with the 6.6L engine, connect the VSS electrical connector (4). 5. Lower the vehicle. 6. Check the transmission fluid level. Add if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 5195 Vehicle Speed Sensor: Service and Repair Automatic Transmission - 4L60-E/4L65-E Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). 4. Notice: Refer to Fastener Notice in Service Precautions. Install the VSS bolt (2). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Manual Transmission - NV 3500 > Page 5196 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest for Catalytic Converter: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH Catalytic Converter: Customer Interest Exhaust System - Moan/Vibration at 55-60 MPH Bulletin No.: 05-06-05-002 Date: July 27, 2005 TECHNICAL Subject: Exhaust Moan/Vibration (Replace Converter Assembly and Exhaust Muffler Assembly) Models: 2004-2005 Chevrolet Silverado 2500HD/3500HD Series Crew Cab Short Box Pickups 2004-2005 GMC Sierra 2500HD/3500HD Series Crew Cab Short Box Pickups with 6.6L Diesel Engine (VIN 2 - RPO LLY) Condition Some customers may comment on a moan or vibration at vehicle speeds approximately 87-97 km/h (55-60 mph) and at approximately 1700-1800 RPM. Correction Replace the catalytic converter assembly and exhaust muffler assembly using the procedure listed below. 1. Raise and suitably support the vehicle. 2. Remove the spare tire. 3. Install adjustable jack stands under the rear axle. 4. Remove the rear axle vent hose from the rear axle. 5. Remove the vent hose swivel clip from the rear brake crossover pipe. 6. Remove the rear shock absorbers lower bolts and nuts. 7. Lower the rear axle using the adjustable jack stands. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest for Catalytic Converter: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 5206 8. Loosen the catalytic converter coupling nuts. 9. With the aid of an assistant, support the exhaust muffler. 10. Gently pry up the catalytic converter coupling clip (1) (on the muffler end) in order to disengage the locator button (3) from the coupling clip. 11. With the aid of an assistant, slide the muffler rearward until the locator button is fully disengaged. 12. Remove the insulators from the frame hangers. 13. With the aid of an assistant, remove the muffler assembly from the vehicle. 14. Support the transmission with a suitable transmission jack. 15. Remove the transmission mount to transmission support nuts. 16. Raise the transmission off of the transmission support. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest for Catalytic Converter: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 5207 17. Remove the transmission support crossmember bolts. 18. Remove the transmission support crossmember. 19. Loosen the exhaust pipe clamp. 20. Slide the exhaust pipe clamp up onto the exhaust pipe. 21. Slide the catalytic converter hanger out of the insulator. 22. Remove the catalytic converter. 23. Apply water based lubricant to the exhaust pipe hanger bracket, in order to aid in installation. 24. Slide the catalytic converter hanger into the insulator. Important: Ensure that the manifold pipe is square to the exhaust pipe adapter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest for Catalytic Converter: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 5208 25. Slide the exhaust pipe clamp down and around the pipe connection. 26. Tighten the exhaust pipe clamp. Tighten Tighten the clamp to 40 N.m (30 lb ft). 27. Lower the transmission onto the transmission support. 28. Install the transmission mount to transmission support nuts. Tighten Tighten the bolts to 40 N.m (30 lb ft). 29. Remove the support from the transmission. 30. With the aid of an assistant, align the new muffler, locator button (3) to the catalytic converter coupling groove (2). 31. Install the muffler until the locator button is fully engaged by the coupling clip (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest for Catalytic Converter: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 5209 Important: Apply lubricant to the insulators to aid in installation. 32. Install the insulators to the frame hangers. 33. Tighten the catalytic converter coupling nuts until snug. 34. Once sung, tighten the catalytic converter coupling nuts. Tighten Tighten the nuts to 45 Nm (33 lb-ft.). 35. Raise the rear axle using the adjustable jack stands. 36. Install the rear shock absorbers lower bolts and nuts. Tighten Tighten the bolts to 95 N.m (70 lb ft). 37. Install the rear axle vent hose to the rear axle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest for Catalytic Converter: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 5210 38. Connect the vent hose swivel clip to the rear brake crossover pipe. 39. Remove the adjustable jack stands from under the rear axle. 40. Install the spare tire. 41. Lower the vehicle. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH Catalytic Converter: All Technical Service Bulletins Exhaust System - Moan/Vibration at 55-60 MPH Bulletin No.: 05-06-05-002 Date: July 27, 2005 TECHNICAL Subject: Exhaust Moan/Vibration (Replace Converter Assembly and Exhaust Muffler Assembly) Models: 2004-2005 Chevrolet Silverado 2500HD/3500HD Series Crew Cab Short Box Pickups 2004-2005 GMC Sierra 2500HD/3500HD Series Crew Cab Short Box Pickups with 6.6L Diesel Engine (VIN 2 - RPO LLY) Condition Some customers may comment on a moan or vibration at vehicle speeds approximately 87-97 km/h (55-60 mph) and at approximately 1700-1800 RPM. Correction Replace the catalytic converter assembly and exhaust muffler assembly using the procedure listed below. 1. Raise and suitably support the vehicle. 2. Remove the spare tire. 3. Install adjustable jack stands under the rear axle. 4. Remove the rear axle vent hose from the rear axle. 5. Remove the vent hose swivel clip from the rear brake crossover pipe. 6. Remove the rear shock absorbers lower bolts and nuts. 7. Lower the rear axle using the adjustable jack stands. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 5216 8. Loosen the catalytic converter coupling nuts. 9. With the aid of an assistant, support the exhaust muffler. 10. Gently pry up the catalytic converter coupling clip (1) (on the muffler end) in order to disengage the locator button (3) from the coupling clip. 11. With the aid of an assistant, slide the muffler rearward until the locator button is fully disengaged. 12. Remove the insulators from the frame hangers. 13. With the aid of an assistant, remove the muffler assembly from the vehicle. 14. Support the transmission with a suitable transmission jack. 15. Remove the transmission mount to transmission support nuts. 16. Raise the transmission off of the transmission support. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 5217 17. Remove the transmission support crossmember bolts. 18. Remove the transmission support crossmember. 19. Loosen the exhaust pipe clamp. 20. Slide the exhaust pipe clamp up onto the exhaust pipe. 21. Slide the catalytic converter hanger out of the insulator. 22. Remove the catalytic converter. 23. Apply water based lubricant to the exhaust pipe hanger bracket, in order to aid in installation. 24. Slide the catalytic converter hanger into the insulator. Important: Ensure that the manifold pipe is square to the exhaust pipe adapter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 5218 25. Slide the exhaust pipe clamp down and around the pipe connection. 26. Tighten the exhaust pipe clamp. Tighten Tighten the clamp to 40 N.m (30 lb ft). 27. Lower the transmission onto the transmission support. 28. Install the transmission mount to transmission support nuts. Tighten Tighten the bolts to 40 N.m (30 lb ft). 29. Remove the support from the transmission. 30. With the aid of an assistant, align the new muffler, locator button (3) to the catalytic converter coupling groove (2). 31. Install the muffler until the locator button is fully engaged by the coupling clip (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 5219 Important: Apply lubricant to the insulators to aid in installation. 32. Install the insulators to the frame hangers. 33. Tighten the catalytic converter coupling nuts until snug. 34. Once sung, tighten the catalytic converter coupling nuts. Tighten Tighten the nuts to 45 Nm (33 lb-ft.). 35. Raise the rear axle using the adjustable jack stands. 36. Install the rear shock absorbers lower bolts and nuts. Tighten Tighten the bolts to 95 N.m (70 lb ft). 37. Install the rear axle vent hose to the rear axle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 05-06-05-002 > Jul > 05 > Exhaust System - Moan/Vibration at 55-60 MPH > Page 5220 38. Connect the vent hose swivel clip to the rear brake crossover pipe. 39. Remove the adjustable jack stands from under the rear axle. 40. Install the spare tire. 41. Lower the vehicle. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 5221 Catalytic Converter: Service and Repair Catalytic Converter Replacement (6.6L Engine) Removal Procedure 1. Raise and suitably support the vehicle. 2. Support the transmission with a suitable transmission jack. 3. Remove the transmission mount to transmission support nuts. 4. Raise the transmission off of the transmission support. 5. Remove the transmission support crossmember bolts. 6. Remove the transmission support crossmember. 7. If equipped with the 6.6L engine, remove the exhaust muffler nuts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 5222 8. If equipped with a 6.6L engine, loosen the exhaust pipe clamp. 9. Slide the exhaust pipe clamp up onto the exhaust pipe adapter. 10. If equipped with a 6.6L engine, remove the catalytic converter. 11. Slide the catalytic converter hanger out of the exhaust pipe hanger bracket. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 5223 1. If equipped with a 6.6L engine, install the catalytic converter. 2. Apply water based lubricant to the exhaust pipe hanger bracket, in order to aid in installation. 3. Slide the catalytic converter hanger into the exhaust pipe hanger bracket. 4. If equipped with the 6.6L engine, install the exhaust muffler nuts until snug. 5. Important: Ensure that the manifold pipe is square to the exhaust pipe adapter. If equipped with a 6.6L engine, slide the exhaust pipe clamp down and around the pipe connection. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the exhaust pipe clamp and muffler nuts. ^ Tighten the clamp to 40 Nm (30 ft. lbs.). ^ Tighten the nuts to 40 Nm (30 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 5224 7. Lower the transmission onto the transmission support. 8. Install the transmission mount to transmission support nuts. Tighten the bolts to 40 Nm (30 ft. lbs.). 9. Remove the support from the transmission. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Emissions Fluid (DEF) System > System Information > Technical Service Bulletins > Emissions - EGR Cooler Pressure Tester Adapter Diesel Emissions Fluid (DEF) System: Technical Service Bulletins Emissions - EGR Cooler Pressure Tester Adapter INFORMATION Bulletin No.: 08-06-04-003B Date: April 18, 2011 Subject: New Tool Availability - EN-48974 - EGR Cooler Pressure Tester Adapter Set to Diagnose Duramax(TM) Diesel Engine EGR Cooler Engine Coolant Leaks into Combustion Chamber Models: 2002-2012 Chevrolet Silverado 2004-2009 Chevrolet Kodiak C4500-C5500 Series 2006-2012 Chevrolet Express Vans 2002-2012 GMC Sierra 2004-2009 GMC TopKick C4500-C5500 Series 2006-2012 GMC Savana Vans Equipped with 6.6L Duramax(TM) Diesel Engine (VINs 1, 2, D, 6, L, 8 - RPOs LB7 (CA Emissions), LLY, LBZ, LMM, LML, LGH) Please Refer to GWM/IVH Attention: The graphics contained in this bulletin for clarity show the EGR cooler connections to J-46091 and EN-48974 on a workbench. The connections are the same with on-vehicle service. Supercede: This bulletin is being revised to add supplemental kit EN-48974-20, 2011-2012 model year vehicles, add graphics and update the EGR cooler testing information. Please discard Corporate Bulletin Number 08-06-04-003A (Section 06 - Engine/Propulsion System). An EGR Cooler Pressure Tester Adapter Set, EN-48974, was shipped essential to dealers in December 2007 to diagnose EGR cooler engine coolant leaks on all Duramax(TM) engines equipped with an EGR system. This adapter set is designed to be used with J-46091-1 - Charge Air Cooler Tester Regulator to pressurize the EGR cooler with shop air and monitor it for leakage. Important Leaks from the EGR cooler may allow coolant to pass through the exhaust system and enter the combustion chambers on the right bank cylinders. Failure to inspect the EGR cooler for leaks may lead to a misdiagnosis for coolant in the combustion chamber. EN-48974 - EGR Cooler Pressure Tester Adapter Set 544259 (Qty 2) 19 mm (3/4 Inch) Hose Clamps EN-48974-3 (Qty 1) 19 mm (3/4 Inch) EGR Cooler Hose Adapter EN-48974-4 (Qty 1) 19 mm (3/4 Inch) Cap Plug EN-48974-1 (Qty 1) 15.9 mm (5/8 Inch) EGR Cooler Hose Adapter EN-48974-2 (Qty 1) 15.9 mm (5/8 Inch) Cap Plug 544258 (Qty 2) 15.9 mm (5/8 Inch) Hose Clamps In December 2010 another supplement to the EGR Cooler Pressure Tester Adapter Set, EN-48974-20, was shipped essential to dealers to diagnose EGR cooler engine coolant leaks on all 2010-2011 Duramax(TM) 6.6L engines equipped with multiple cooler EGR system. This supplement gives the test adapter set a larger variety of sizes to accommodate the newer style coolers that have multiple ports. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Emissions Fluid (DEF) System > System Information > Technical Service Bulletins > Emissions - EGR Cooler Pressure Tester Adapter > Page 5229 EN-48974-20 - EGR Cooler Pressure Tester Adapter Set EN-48974-21 (Qty 1) 12.7 mm (1/2 Inch) EGR Cooler Hose Adapter EN-48974-22 (Qty 1) 8 mm (5/16 Inch) EGR Cooler Hose Adapter 544259 (Qty 2) 19 mm (3/4 Inch) Hose Clamps 553016 (Qty 1) 12.7 mm (1/2 Inch) Cap Plug 544258 (Qty 3) 15.9 mm (5/8 Inch) Hose Clamps 553015 (Qty 1) 8 mm (5/16 Inch) Cap Plug 553017 (Qty 1) 22.2 mm (7/8 Inch) Cap Plug Important If an investigation of loss of engine coolant leads to coolant found in one or multiple cylinders on the right bank, YOU MUST test the EGR cooler for leakage BEFORE attempting any engine repair. The cylinders affected will depend on which exhaust valves were open at the time of engine shutdown. 1. Partially drain the engine coolant to allow removal of the EGR cooler coolant hoses. Refer to Cooling System Draining and Filling in SI. 2. Select the appropriate size EGR Cooler Hose Adapter from the EN-48974 - EGR Cooler Pressure Tester Adapter Set. 3. Install the EGR Cooler Hose Adapter (1) and tighten the clamp (2) on the EGR cooler hose barb as shown. 4. Select the appropriate size Cap Plug(s) from the EN-48974 - EGR Cooler Pressure Tester Adapter Set. 5. Install the Cap Plug(s) (1) and tighten the clamp(s) (2) on the EGR cooler hose barb(s) as shown. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Emissions Fluid (DEF) System > System Information > Technical Service Bulletins > Emissions - EGR Cooler Pressure Tester Adapter > Page 5230 6. Connect the hose fitting (1) of pressure tester J-46091-1 Charge Air Cooler Tester Regulator to the EGR Cooler Hose Adapter (2) on the EGR cooler as shown. Important SOME J-46091-1 REGULATORS MAY BE PRESET AT 30 PSI WITH THE ADJUSTING KNOB RIVETED IN PLACE. THE RIVET HEAD MUST BE DRILLED OUT WITH A 5/16" DRILL BIT BEFORE ADJUSTMENT. DO NOT DRILL MORE THAN 1/8" IN DEPTH, OR JUST ENOUGH TO REMOVE THE RIVET HEAD. THE RIVET SHAFT DOES NOT HAVE TO BE REMOVED FROM THE REGULATOR. 7. Back off the regulator on J-46091-1 - Charge Air Cooler Tester Regulator by turning counterclockwise until it stops. 8. Connect J-46091-1 - Charge Air Cooler Tester Regulator to the shop air supply. 9. Open the shutoff valve, then slowly turn the regulator on J-46091-1 clockwise until the gauge reads 42 psi. 10. Close the shutoff valve on J-46091-1 and monitor the gauge for pressure decay for 5 minutes. ‹› If the gauge indicates pressure decay, replace the EGR cooler. ‹› If the gauge does not indicate pressure decay, proceed to Step 11. 11. Continue performing the engine diagnosis to determine the source of the coolant leak. 12. Install the EGR cooler. Refer to Exhaust Gas Recirculation Valve and Cooler Installation in SI. 13. Fill the engine coolant to the proper level. Refer to Cooling System Draining and Filling in SI. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations G302 (With RPO Code HVY) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations Chassis And License Lamp Harnesses Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > Emissions - EGR Cooler Pressure Tester Adapter EGR Cooler: Technical Service Bulletins Emissions - EGR Cooler Pressure Tester Adapter INFORMATION Bulletin No.: 08-06-04-003B Date: April 18, 2011 Subject: New Tool Availability - EN-48974 - EGR Cooler Pressure Tester Adapter Set to Diagnose Duramax(TM) Diesel Engine EGR Cooler Engine Coolant Leaks into Combustion Chamber Models: 2002-2012 Chevrolet Silverado 2004-2009 Chevrolet Kodiak C4500-C5500 Series 2006-2012 Chevrolet Express Vans 2002-2012 GMC Sierra 2004-2009 GMC TopKick C4500-C5500 Series 2006-2012 GMC Savana Vans Equipped with 6.6L Duramax(TM) Diesel Engine (VINs 1, 2, D, 6, L, 8 - RPOs LB7 (CA Emissions), LLY, LBZ, LMM, LML, LGH) Please Refer to GWM/IVH Attention: The graphics contained in this bulletin for clarity show the EGR cooler connections to J-46091 and EN-48974 on a workbench. The connections are the same with on-vehicle service. Supercede: This bulletin is being revised to add supplemental kit EN-48974-20, 2011-2012 model year vehicles, add graphics and update the EGR cooler testing information. Please discard Corporate Bulletin Number 08-06-04-003A (Section 06 - Engine/Propulsion System). An EGR Cooler Pressure Tester Adapter Set, EN-48974, was shipped essential to dealers in December 2007 to diagnose EGR cooler engine coolant leaks on all Duramax(TM) engines equipped with an EGR system. This adapter set is designed to be used with J-46091-1 - Charge Air Cooler Tester Regulator to pressurize the EGR cooler with shop air and monitor it for leakage. Important Leaks from the EGR cooler may allow coolant to pass through the exhaust system and enter the combustion chambers on the right bank cylinders. Failure to inspect the EGR cooler for leaks may lead to a misdiagnosis for coolant in the combustion chamber. EN-48974 - EGR Cooler Pressure Tester Adapter Set 544259 (Qty 2) 19 mm (3/4 Inch) Hose Clamps EN-48974-3 (Qty 1) 19 mm (3/4 Inch) EGR Cooler Hose Adapter EN-48974-4 (Qty 1) 19 mm (3/4 Inch) Cap Plug EN-48974-1 (Qty 1) 15.9 mm (5/8 Inch) EGR Cooler Hose Adapter EN-48974-2 (Qty 1) 15.9 mm (5/8 Inch) Cap Plug 544258 (Qty 2) 15.9 mm (5/8 Inch) Hose Clamps In December 2010 another supplement to the EGR Cooler Pressure Tester Adapter Set, EN-48974-20, was shipped essential to dealers to diagnose EGR cooler engine coolant leaks on all 2010-2011 Duramax(TM) 6.6L engines equipped with multiple cooler EGR system. This supplement gives the test adapter set a larger variety of sizes to accommodate the newer style coolers that have multiple ports. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > Emissions - EGR Cooler Pressure Tester Adapter > Page 5244 EN-48974-20 - EGR Cooler Pressure Tester Adapter Set EN-48974-21 (Qty 1) 12.7 mm (1/2 Inch) EGR Cooler Hose Adapter EN-48974-22 (Qty 1) 8 mm (5/16 Inch) EGR Cooler Hose Adapter 544259 (Qty 2) 19 mm (3/4 Inch) Hose Clamps 553016 (Qty 1) 12.7 mm (1/2 Inch) Cap Plug 544258 (Qty 3) 15.9 mm (5/8 Inch) Hose Clamps 553015 (Qty 1) 8 mm (5/16 Inch) Cap Plug 553017 (Qty 1) 22.2 mm (7/8 Inch) Cap Plug Important If an investigation of loss of engine coolant leads to coolant found in one or multiple cylinders on the right bank, YOU MUST test the EGR cooler for leakage BEFORE attempting any engine repair. The cylinders affected will depend on which exhaust valves were open at the time of engine shutdown. 1. Partially drain the engine coolant to allow removal of the EGR cooler coolant hoses. Refer to Cooling System Draining and Filling in SI. 2. Select the appropriate size EGR Cooler Hose Adapter from the EN-48974 - EGR Cooler Pressure Tester Adapter Set. 3. Install the EGR Cooler Hose Adapter (1) and tighten the clamp (2) on the EGR cooler hose barb as shown. 4. Select the appropriate size Cap Plug(s) from the EN-48974 - EGR Cooler Pressure Tester Adapter Set. 5. Install the Cap Plug(s) (1) and tighten the clamp(s) (2) on the EGR cooler hose barb(s) as shown. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > Emissions - EGR Cooler Pressure Tester Adapter > Page 5245 6. Connect the hose fitting (1) of pressure tester J-46091-1 Charge Air Cooler Tester Regulator to the EGR Cooler Hose Adapter (2) on the EGR cooler as shown. Important SOME J-46091-1 REGULATORS MAY BE PRESET AT 30 PSI WITH THE ADJUSTING KNOB RIVETED IN PLACE. THE RIVET HEAD MUST BE DRILLED OUT WITH A 5/16" DRILL BIT BEFORE ADJUSTMENT. DO NOT DRILL MORE THAN 1/8" IN DEPTH, OR JUST ENOUGH TO REMOVE THE RIVET HEAD. THE RIVET SHAFT DOES NOT HAVE TO BE REMOVED FROM THE REGULATOR. 7. Back off the regulator on J-46091-1 - Charge Air Cooler Tester Regulator by turning counterclockwise until it stops. 8. Connect J-46091-1 - Charge Air Cooler Tester Regulator to the shop air supply. 9. Open the shutoff valve, then slowly turn the regulator on J-46091-1 clockwise until the gauge reads 42 psi. 10. Close the shutoff valve on J-46091-1 and monitor the gauge for pressure decay for 5 minutes. ‹› If the gauge indicates pressure decay, replace the EGR cooler. ‹› If the gauge does not indicate pressure decay, proceed to Step 11. 11. Continue performing the engine diagnosis to determine the source of the coolant leak. 12. Install the EGR cooler. Refer to Exhaust Gas Recirculation Valve and Cooler Installation in SI. 13. Fill the engine coolant to the proper level. Refer to Cooling System Draining and Filling in SI. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair EGR Tube: Service and Repair EXHAUST GAS RECIRCULATION (EGR) VALVE COOLER TUBE REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold cover. 2. Remove the air cleaner outlet duct. 3. Loosen the charged air cooler outlet duct to intake hose clamp. IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting. 4. Remove the charged air cooler outlet duct from the intake. 5. Drain the cooling system. 6. Remove the positive crankcase ventilation (PCV) hose/pipe. 7. If necessary, remove the tie strap from the electrical harness. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Page 5249 8. Remove the air inlet tube to intake manifold tube bolt and nut. 9. Remove the air inlet tube nuts. 10. Remove the air inlet tube. 11. Disconnect the exhaust gas recirculation (EGR) valve electrical connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Page 5250 12. Disconnect the EGR cooler tube heater hose. 13. Remove the EGR coolant pipe bolts. 14. Remove the EGR coolant pipe. 15. Remove the rear EGR cooler tube bolts. 16. Remove the EGR cooler tube bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Page 5251 17. Remove the EGR cooler tube. INSTALLATION PROCEDURE 1. Install the EGR cooler tube. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the EGR cooler tube bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Page 5252 Tighten Tighten the bolts to 50 N.m (37 lb ft). 3. Install the rear EGR cooler tube bolts. Tighten Tighten the bolts to 20 N.m (15 lb ft). 4. Install the EGR coolant pipe. 5. Install the EGR coolant pipe bolts. Tighten Tighten the bolts to 25 N.m (18 lb ft). 6. Connect the EGR cooler tube heater hose. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Page 5253 7. Connect the EGR valve electrical connector. 8. Install the air inlet tube. 9. Install the air inlet tube nuts. Tighten Tighten the nuts to 25 N.m (18 lb ft). 10. Install the air inlet tube to intake manifold tube bolt and nut. Tighten Tighten the bolt/nut to 10 N.m (89 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Page 5254 11. If necessary, install a tie strap to the electrical harness. 12. Install the PCV hose/pipe. IMPORTANT: Lubricate the end of the duct prior to installation. 13. Install the charged air cooler outlet duct to the intake. 14. Tighten the charged air cooler outlet duct to intake hose clamp. Tighten Tighten the clamp to 6 N.m (53 lb in). 15. Install the intake manifold cover. 16. Fill the cooling system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams Exhaust Gas Recirculation (EGR) Valve Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Page 5258 EGR Valve: Service and Repair EXHAUST GAS RECIRCULATION (EGR) VALVE REPLACEMENT REMOVAL PROCEDURE 1. Remove the exhaust gas recirculation (EGR) cooler tube. 2. Remove the EGR valve bolts (3). 3. Remove the EGR valve/solenoid assembly (1). 4. Remove and discard the EGR valve/solenoid assembly gasket (2). INSTALLATION PROCEDURE 1. Install a NEW EGR valve/solenoid assembly gasket (2). 2. Install the EGR valve/solenoid assembly (1). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the EGR valve bolts. Tighten Tighten the bolts to 20 N.m (15 lb ft). 4. Install the EGR cooler tube. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair PCV Valve Hose: Service and Repair Crankcase Ventilation Hoses/Pipes Replacement Removal Procedure 1. Remove the intake manifold cover. Important: After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects. 2. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1). 3. Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting. Remove the charged air cooler inlet duct connector (4) from the turbocharger. 4. Loosen the charged air cooler outlet duct to intake hose clamp. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair > Page 5263 5. Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting. Remove the charged air cooler outlet duct from the intake. 6. Reposition the positive crankcase ventilation (PCV) hose clamp. 7. Remove the PCV hose from the air inlet pipe. 8. Remove the PCV hose from the clip on the top of the turbocharger. 9. Remove the left PCV hose/pipe bolt. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair > Page 5264 10. Remove the right PCV hose/pipe bolt. 11. Remove the PCV hose/pipe. Installation Procedure 1. Install the PCV hose/pipe. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the right PCV hose/pipe bolt. Tighten the bolt to 18 Nm (13 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair > Page 5265 3. Install the left PCV hose/pipe bolt. Tighten the bolt to 18 Nm (13 ft. lbs.). 4. Install the PCV hose to the air inlet pipe. 5. Position the PCV hose clamp. 6. Install the PCV hose to the clip on the top of the turbocharger. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair > Page 5266 7. Important: Lubricate the end of the duct prior to installation. Install the charged air cooler outlet duct to the intake. 8. Tighten the charged air cooler outlet duct to intake hose clamp. Tighten the clamp to 6 Nm (53 inch lbs.). 9. Remove the tape from the turbocharger openings. Important: Lubricate the end of the duct prior to installation. 10. Install the charged air cooler inlet duct connector (4) to the turbocharger. 11. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1). Tighten the clamp to 6 Nm (53 inch lbs.). 12. Install the intake manifold cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair > Left Positive Crankcase Ventilation Valve: Service and Repair Left Positive Crankcase Ventilation (PCV) Valve Replacement (Left) Removal Procedure 1. Important: After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1). 2. Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting. Remove the charged air cooler inlet duct connector (4) from the turbocharger. 3. Remove the positive crankcase ventilation (PCV) cover screws. 4. Remove the PCV cover, diaphragm, and spring. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair > Left > Page 5271 5. Clean and inspect the cover, diaphragm, and spring. 6. Discard the diaphragm if damage is found. Installation Procedure 1. Install the spring, diaphragm, and cover. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the PCV cover screws. Tighten the screws to 4 Nm (35 inch lbs.). 3. Remove the tape from the turbocharger openings. Important: Lubricate the end of the duct prior to installation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair > Left > Page 5272 4. Install the charged air cooler inlet duct connector (4) to the turbocharger. 5. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1). Tighten the clamp to 6 Nm (53 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair > Left > Page 5273 Positive Crankcase Ventilation Valve: Service and Repair Right Positive Crankcase Ventilation (PCV) Valve Replacement (Right) Removal Procedure 1. Remove the air cleaner outlet duct. 2. Loosen the charged air cooler outlet duct to intake hose clamp. 3. Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting. Remove the charged air cooler outlet duct from the intake. 4. Remove the fuel filter bracket bolts. 5. Position the fuel filter assembly out of the way. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair > Left > Page 5274 6. Remove the Positive Crankcase Ventilation (PCV) cover screws. 7. Remove the PCV cover, diaphragm, and spring. 8. Clean and inspect the cover, diaphragm and spring. 9. Discard the diaphragm if damage is found. Installation Procedure 1. Install the spring, diaphragm and cover. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the PCV cover screws. Tighten the screws to 4 Nm (35 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair > Left > Page 5275 3. Position the fuel filter assembly to the engine. 4. Install the fuel filter bracket bolts. Tighten the bolts to 21 Nm (15 ft. lbs.). 5. Important: Lubricate the end of the duct prior to installation. Install the charged air cooler outlet duct to the intake. 6. Tighten the charged air cooler outlet duct to intake hose clamp. Tighten the clamp to 6 Nm (53 inch lbs.). 7. Install the air cleaner outlet duct. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations FUEL SCHRADER VALVE The Fuel Schrader Valve is located on the right front of the engine, on the right upper valve rocker Arm cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Information Not Supplied By The Manufacturer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5287 Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5288 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SYSTEM DESCRIPTION The accelerator pedal position (APP) system along with the vehicle electronics and components is used to calculate and control the amount of acceleration and deceleration via fuel injector control. This eliminates the need for a mechanical cable attachment from the accelerator pedal to a throttle body. The APP system includes, but is not limited to, the following components : - The accelerator pedal position (APP) sensor assembly - The engine control module (ECM) Accelerator Pedal Position (APP) Sensor The accelerator pedal position (APP) sensor is mounted on the accelerator pedal control assembly. The sensor is made up of 3 individual sensors within one housing. Three separate signal, low reference, and 5-volt reference circuits are used in order to interface the accelerator pedal sensor assembly with the ECM. Each sensor has a unique functionality to determine pedal position. The ECM uses the APP sensor to determine the amount of acceleration or deceleration desired by the person driving the vehicle. The APP sensor 1 voltage should increase as the accelerator pedal is depressed, from below 1.0 volt at 0 pedal travel to above 2 volts at 100 percent pedal travel. APP sensor 2 voltage should decrease from above 4 volts at 0 pedal travel to below 3.0 volts at 100 percent pedal travel. APP sensor 3 voltage should decrease from above 3.8 volts at 0 percent pedal travel to below 3.3 volts at 100 percent pedal travel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5289 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION (APP) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector. 3. Reposition the carpet to access the lower nut. 4. Remove the accelerator pedal nuts. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5290 1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Service Precautions. 2. Install the accelerator pedal nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Connect the APP sensor electrical connector. 4. Reposition the carpet. 5. Install the CPA retainer. 6. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 7. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle and a wide open throttle (WOT). 8. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 9. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Air Cleaner Fresh Air Duct/Hose: Customer Interest Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5300 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5301 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5302 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5303 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5304 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5305 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5306 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Air Cleaner Fresh Air Duct/Hose: All Technical Service Bulletins Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5312 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5313 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5314 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5315 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5316 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5317 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5318 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Page 5319 Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR CLEANER OUTLET DUCT REPLACEMENT REMOVAL PROCEDURE 1. Loosen the outlet duct clamps at the turbocharger and the mass air flow (MAF)/intake air temperature (IAT) sensor. 2. Remove the air cleaner outlet duct. INSTALLATION PROCEDURE IMPORTANT: The air cleaner outlet duct must be fully seated against the positive stop feature on the turbocharger inlet. 1. Install the air cleaner outlet duct. NOTE: Refer to Fastener Notice in Service Precautions. 2. Tighten the outlet duct clamps at the turbocharger and the MAF/IAT sensor. Tighten Tighten the clamps to 6 N.m (53 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Restriction Indicator > Component Information > Description and Operation Air Cleaner Restriction Indicator: Description and Operation AIR CLEANER RESTRICTION INDICATOR The air cleaner restriction indicator is located on the air cleaner housing. If the area inside of the clear section is green, no air filter service is required. If the area inside the clear section is orange and Change Air Filter appears, replace the air filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Air Filter Element: Customer Interest Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5331 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5332 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5333 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5334 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5335 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5336 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5337 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 5342 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Air Filter Element: All Technical Service Bulletins Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5348 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5349 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5350 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5351 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5352 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5353 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 5354 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 5359 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 05-00-90-001 > Jan > 05 > Diesel Engine - IMPORTANT Correct Air Filter Usage Air Filter Element: All Technical Service Bulletins Diesel Engine - IMPORTANT Correct Air Filter Usage Bulletin No.: 05-00-90-001 Date: January 05, 2005 INFORMATION Subject: Information on the Proper Air Filter for the Duramax(R) Diesel Models: 2001-2005 Chevrolet Silverado 2001-2005 GMC Sierra with 6.6L Duramax(R) Diesel Engine (VINs 1, 2 - RPOs LB7, LLY) The Duramax(R) air filter, P/N 25332443, is specific to the diesel engine due to the operating characteristics of a turbo charged diesel engine. The turbo allows for a much greater air volume rate than a normal aspirated engine. The Duramax(R) diesel air filter is reinforced to eliminate damage from the increased airflow of the turbo. The reinforcement is visually identified by the five ribs of epoxy that lies across the pleats of the clean side of the filter. If the correct air filter is not used, the filter may collapse or be torn in a Duramax(R) application. This damage will allow dust and dirt to be ingested into the turbo and engine causing serious damage. This damage is usually identified at the turbo vanes as well as extreme wear in the cylinder walls of the engine. There is evidence of gasoline engine air filters being used in the Duaramax(R) application. The 8.1 gas air filter, P/N 25313349, will fit into the air box of the Duramax(R) diesel; however, it does not have the required reinforcement of the diesel air filter. The 8.1 liter gas engine air filter should never be used in a Duramax(R) diesel engine. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 05-00-90-001 > Jan > 05 > Diesel Engine - IMPORTANT Correct Air Filter Usage Air Filter Element: All Technical Service Bulletins Diesel Engine - IMPORTANT Correct Air Filter Usage Bulletin No.: 05-00-90-001 Date: January 05, 2005 INFORMATION Subject: Information on the Proper Air Filter for the Duramax(R) Diesel Models: 2001-2005 Chevrolet Silverado 2001-2005 GMC Sierra with 6.6L Duramax(R) Diesel Engine (VINs 1, 2 - RPOs LB7, LLY) The Duramax(R) air filter, P/N 25332443, is specific to the diesel engine due to the operating characteristics of a turbo charged diesel engine. The turbo allows for a much greater air volume rate than a normal aspirated engine. The Duramax(R) diesel air filter is reinforced to eliminate damage from the increased airflow of the turbo. The reinforcement is visually identified by the five ribs of epoxy that lies across the pleats of the clean side of the filter. If the correct air filter is not used, the filter may collapse or be torn in a Duramax(R) application. This damage will allow dust and dirt to be ingested into the turbo and engine causing serious damage. This damage is usually identified at the turbo vanes as well as extreme wear in the cylinder walls of the engine. There is evidence of gasoline engine air filters being used in the Duaramax(R) application. The 8.1 gas air filter, P/N 25313349, will fit into the air box of the Duramax(R) diesel; however, it does not have the required reinforcement of the diesel air filter. The 8.1 liter gas engine air filter should never be used in a Duramax(R) diesel engine. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 5369 Air Filter Element: Service Precautions NOTE: This information is contained within GM Bulletin 05-00-90-001 dated January 5, 2005. Subject: Information on the Proper Air Filter for the Duramax(R) Diesel Models: 2001-2005 Chevrolet Silverado and GMC Sierra with 6.6L Duramax(R) Diesel Engines (VINs 1, 2 - RPOs LB7, LLY) The Duramax(R) air filter. P/N 25332433, is specific to the diesel engine due to the operating characteristics of a turbocharged diesel engine. The turbo allows for a much greater air volume rate than a normally aspirated engine. The Duramax(R) diesel air filter is reinforced to eliminate damage from the increased airflow of the turbo. The reinforcement is visually identified by the five ribs of epoxy that lie across the pleats of the clean side of the filter. If the correct air filter is not used, the filter may collapse or be torn in a Duramax(R) application. This damage will allow dust and dirt to be ingested into the turbo and engine causing serious damage. This damage is usually identified at the turbo vanes as well as extreme wear in the cylinder walls of the engine. There is evidence of gasoline engine air filters being used in the Duramax(R) application. The 8.1 gas air filter, P/N 25313349 will fit into the air box of the Duramax(R) diesel; however, it does not have the required reinforcement of the diesel air filter. The 8.1 liter gas engine air filter should never be used in a Duramax(R) diesel engine. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 5370 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector (1). 2. Loosen the screws holding the air cleaner housing halves together. 3. Separate the housing halves and remove the air filter element. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 5371 1. Install the air filter element into the lower air cleaner housing. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the upper housing cover and tighten the screws. Tighten Tighten the screws to 4 N.m (35 lb in). 3. Connect the MAF/IAT sensor electrical connector (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Mass Air Flow (MAF) Sensor: Locations Right Side Of The Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 5375 Right Side Of Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 5376 Intake Air Temperature (IAT)/Mass Airflow (MAF) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 5377 Mass Air Flow (MAF) Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector (1). 2. Remove the MAF/IAT sensor TORX(R) screws. 3. Remove the MAF/IAT sensor (1). INSTALLATION PROCEDURE 1. Install the MAF/IAT sensor (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 5378 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the MAF/IAT sensor TORX(R) screws. Tighten Tighten the screws to 8 N.m (70 lb in). 3. Connect the MAF/IAT sensor electrical connector (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Component Information > Description and Operation > Fuel Injection Pump Diesel MFI Pump: Description and Operation Fuel Injection Pump FUEL INJECTION PUMP Fuel Injection Pump The fuel injection pump is a mechanical high pressure pump. The fuel injection pump is located below the intake manifold. Fuel is pumped from the fuel tank to the fuel rails at a specified pressure. Fuel pressure is regulated by a valve on the inlet of the fuel pump, controlled by the ECM. Excess fuel from the fuel injection pump returns to the fuel tank through the fuel return pipe and a fuel cooler. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Component Information > Description and Operation > Fuel Injection Pump > Page 5383 Diesel MFI Pump: Description and Operation Fuel Balance Pump AUXILIARY FUEL PUMP (BALANCE) On vehicles equipped with dual fuel tanks, an electric fuel pump is located on the left frame rail. This fuel pump is powered by the fuel pump relay that is controlled by the ECM. Fuel is transferred from the auxiliary fuel tank to the primary fuel tank in order to ensure all of the usable fuel volume is available to the fuel injection pump. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Component Information > Service and Repair > Fuel Injection Pump Diesel MFI Pump: Service and Repair Fuel Injection Pump FUEL INJECTION PUMP REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold cover. 2. Disconnect negative battery cable. 3. Remove the air cleaner outlet duct. 4. Remove the fuel injection control module. 5. Drain the cooling system. 6. Remove the fan. 7. Remove the battery cable junction block bolt (1) from the power steering pump bracket. 8. Reposition the battery cables out of the way. 9. Disconnect the air conditioning (A/C) compressor clutch electrical connector. 10. Disconnect the A/C cut out switch electrical connector. 11. Remove the A/C compressor bolts. 12. Reposition the A/C compressor, with the hoses attached, to the right side of the engine compartment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Component Information > Service and Repair > Fuel Injection Pump > Page 5386 13. Remove the power steering pump bracket rear bolts (1). 14. Reposition the power steering pump, with the hoses attached, to the right side of the engine compartment. 15. Remove the A/C compressor/power steering pump bracket bolts and bracket. 16. Remove the oil fill tube. 17. Remove the oil level indicator tube bracket bolt. 18. Remove the heater outlet hose bolt from the generator bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Component Information > Service and Repair > Fuel Injection Pump > Page 5387 19. Remove the drive belt tensioner bolt and tensioner. 20. Remove the generator. 21. Remove the generator bracket bolts and bracket. 22. Remove the thermostat housing crossover. 23. Remove the air intake pipe. 24. Disconnect the fuel balance pipe fitting from the right fuel rail. 25. Remove the fuel balance pipe retainer bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Component Information > Service and Repair > Fuel Injection Pump > Page 5388 26. Disconnect the fuel rail inlet pipe from the injection pump and rail. 27. Remove the inlet pipe. 28. Reposition the injection pump hose clamps at the fuel line. 29. Remove the hoses from fuel lines. 30. Remove the fuel injection pump bolts. IMPORTANT: Be careful not to damage any mating surfaces. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Component Information > Service and Repair > Fuel Injection Pump > Page 5389 31. Remove the fuel injection pump from the block. Use 2 screwdrivers to work the pump from the block towards the rear of engine keeping the pump straight. 32. The fuel injection pump may need to be rotated in order to remove it from the vehicle. Preparing The Fuel Injection Pump 1. Hold the fuel pump by the drive gear in a vice with copper jaw liners. 2. Loosen the gear nut until the nut is even with the end of the gear shaft. 3. Remove the gear from the tapered shaft of the injection pump. 4. Separate the injection pump and adapter by removing the 3 bolts and spacers. 5. Inspect the O-ring for damage on the pump adapter and replace, if necessary. Lubricate the O-ring with clean engine oil. 6. Clean all mating surfaces. 7. Install the adapter on the pump. NOTE: Refer to Fastener Notice in Service Precautions. 8. Install the 3 bolts and spacers. Tighten Tighten the bolts to 20 N.m (15 lb ft). 9. Install the gear and nut. Tighten Tighten nut to 70 N.m (52 lb ft). INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Component Information > Service and Repair > Fuel Injection Pump > Page 5390 1. Install the fuel injection pump to the block. 2. Install the fuel injection pump bolts. Tighten Tighten the bolts to 21 N.m (15 lb ft). 3. Install the hoses to fuel lines. 4. Position the injection pump hose clamps at the fuel line. 5. Install the inlet pipe. 6. Connect the fuel rail inlet pipe to the injection pump and rail. Tighten Tighten the fittings to 41 N.m (30 lb ft). 7. Connect the fuel balance pipe fitting to the right fuel rail. Tighten Tighten the fitting to 41 N.m (30 lb ft). 8. Install the fuel balance pipe retainer bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Component Information > Service and Repair > Fuel Injection Pump > Page 5391 9. Install the air intake pipe. 10. Install the thermostat housing crossover. 11. Install the generator bracket and bolts. Tighten Tighten the bolts to 46 N.m (34 lb ft). 12. Install the generator. 13. Install the drive belt tensioner and bolt. Tighten Tighten the bolt to 50 N.m (37 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Component Information > Service and Repair > Fuel Injection Pump > Page 5392 14. Install the heater outlet hose bolt to the generator bracket. Tighten Tighten the bolt to 21 N.m (15 lb ft). 15. Install the oil level indicator tube bracket bolt. Tighten Tighten the bolt to 21 N.m (15 lb ft). 16. Install the oil fill tube. 17. Install the A/C compressor/power steering pump bracket and bolts. Tighten Tighten the bolt to 46 N.m (34 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Component Information > Service and Repair > Fuel Injection Pump > Page 5393 18. Position the power steering pump, with the hoses attached, to the bracket. 19. Install the power steering pump bracket rear bolts (1). Tighten Tighten the bolts to 50 N.m (37 lb ft). 20. Position the A/C compressor, with the hoses attached, to the bracket. 21. Install the A/C compressor bolts. Tighten Tighten the bolts to 50 N.m (37 lb ft). 22. Connect the A/C cut out switch electrical connector. 23. Connect the A/C compressor clutch electrical connector. 24. Position the battery cables to the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Component Information > Service and Repair > Fuel Injection Pump > Page 5394 25. Install the battery cable junction block bolt to the power steering pump bracket. Tighten Tighten the bolts to 9 N.m (80 lb in). 26. Install the fan. 27. Install the fuel injection control module. 28. Fill the cooling system. 29. Install the air cleaner outlet duct. 30. Connect negative battery cable. 31. Install the intake manifold cover. 32. Prime the fuel system. Refer to Fuel System Priming. 33. Start the engine. If the engine stalls, repeat the above step. 34. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada) INFORMATION Bulletin No.: 05-06-04-022G Date: October 27, 2010 Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY Models: 2011 and Prior GM Passenger Cars and Trucks (Canada Only) Supercede: This bulletin is being revised to update the model years and include an additional gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F (Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate Bulletin Number 04-06-04-047I. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB Top Tier Fuel Availability Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent Gasoline in May of 2010. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 5399 Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane grades : Chevron Canada (markets in British Columbia and western Alberta) - Shell Canada (nationally) - Petro-Canada (nationally) - Sunoco-Canada (Ontario) - Esso-Canada (nationally) What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no metallic additives. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent recommendations of Canadian standards and does not contain metallic additives, which can damage vehicle emission control components. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW, General Motors, Honda, Toyota, Volkswagen and Audi. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required or recommended, and no metallic additives are allowed. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency and the intentional addition of metallic additives is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Who should use TOP TIER Detergent Gasoline? All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website, http://www.toptiergas.com/. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 5400 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 5401 Fuel: Technical Service Bulletins Fuel - Information on Fuel Requirements INFORMATION Bulletin No.: 08-06-04-032 Date: May 22, 2008 Subject: Information on Diesel Fuel Requirements - Service Engine Soon (SES) Indicator ON, Loss of Power, Filter Life Percentage Low as a Result of Fuel Filter Plugged/Incorrect Fuel Grade Models: 2001-2008 Chevrolet Express, Silverado 2001-2008 GMC Savana, Sierra with 6.6L Duramax(TM) Diesel Engine (VINs 1, 2, D, 6 -- RPOs LB7, LLY, LB7, LMM) Attention: This bulletin indicates a fuel quality concern that is NOT covered under the new vehicle warranty. If a vehicle exhibits this condition due to poor fuel quality issues, please give a copy of this bulletin to the customer. You should also review the fuel requirements below so that the customer will have an understanding of the proper fuels available. This bulletin is being issued to inform dealers of the proper diesel fuel use requirements. If vehicle concerns related to low rail pressure are experienced and if the Filter Life Percentage is low and/or the DTC indicates a plugged filter, a restricted fuel filter is the most likely cause or contributor to the condition. Filter/fuel supply restriction should be confirmed by measuring the vacuum at the schrader valve/service port. Vacuum readings of 6 in Hg or greater at idle indicate a restricted filter which is in need of service and may be the root cause or a contributor to the conditions being experienced. When the filter is changed and vacuum readings are reduced to a normal range of 2-3 in-Hg, fuel filter restriction cause is confirmed. If the fuel filter is found restricted before its expected replacement interval, the cause may be use of contaminated/dirty fuel, improper fuel, or out of specification fuel. Fuel removed from the filter, lines or tank that is not clear and bright in color (clouded) confirm fuel quality concerns. When concerns are encountered in cold operation, the fuel should be inspected in a cold condition. If the filter can is removed (using a suitable filter cutter), the filter pleat block may be inspected for indications of possible causes of premature plugging. A pleat block with the presence of deposits on the walls and bottom of the filter may indicate use of contaminated or degraded fuel or a filter that has been run significantly beyond its service interval. The presence of significant sediment and/or rust in the can are also signs of the presence of excessive water or contamination. A "slimy" coating on the pleat block filter may indicate the use of an out of specification biodiesel or unapproved bio-fuel (raw vegetable oil, cooking oil, unprocessed oils, etc.). ^ Diesel fuel containing biodiesel in concentrations greater than 5% (B5) is NOT allowable and may contribute to fuel system concerns. Initial use of biodiesel and particularly higher blends may contribute to premature filter plugging from loosening normal levels of gums and varnish on tank, lines, and fuel system components. ^ Biodiesel blends have higher clouding/filter plugging temperatures than base diesel fuels and must be blended for an acceptable clouding performance during cold operation. Fuel suppliers are expected to provide both normal and biodiesel fuels blended properly for the climatic conditions of the region of sale and time of year. Use of "summer" blends in cold seasons due to extended fuel or vehicle storage can result in filter restriction. ^ Biodiesel blends that are stored for extended periods of time, particularly if stored at warm temperature, may deteriorate (oxidize) and contribute to fuel system corrosion and/or filter restriction. ^ The finding of significant water in the filter/water separator, particularly immediately following a tank fill-up, may indicate the introduction of out of specification fuel. The presence of water in diesel fuel storage can support biological growth in diesel fuel which can lead to premature filter plugging. Engine or fuel system repairs resulting from the use of improper fuel, including concentrations of biodiesel that exceed 5%, are NOT covered under the terms of the new vehicle warranty. Restricted fuel filters causing engine/vehicle performance conditions should be paid by the customer and the vehicle fuel requirements reviewed with the vehicle operator. Fuel Requirements Notice: Never use home heating oil or gasoline in your vehicle's diesel engine. They can cause engine damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 5402 The emission control system requires the use of diesel fuel with ultra low-sulfur (0.0015% by weight, or 15 ppm, maximum) content. Both Ultra Low Sulfur Diesel and Low Sulfur Diesel fuels are available in the United States and Ultra Low Sulfur Diesel fuel is available in Canada. However, only higher sulfur diesel fuel is available in Mexico. At a minimum, the diesel fuel you use should meet the latest version of ASTM specification D 975 (Grades No. 2-D or No. 1-D S15 commonly known as Ultra Low Sulfur diesel) in the United States. In addition, the Engine Manufacturers Association (EMA) has identified properties of an improved diesel fuel for better engine performance and durability. Diesel fuels corresponding to the EMA Consensus Position - Joint EMA/TMC Pump Grade Specification for Premium Diesel Fuel, could provide better starting, less noise, and better vehicle performance. If there are questions about the fuel you are using, contact your fuel supplier. In the United States, for best results use No. 2-D diesel fuel year-round (above and below freezing conditions) as oil companies blend No. 2-D fuel to address climate differences. No. 1-D diesel fuel can be used in very cold temperatures (when it stays below 0°F or -18°C); however, it will produce a power and fuel economy loss. Avoid the use of No. 1-D diesel fuel in warm or hot climates. It can result in stalling, poor starting when the engine is hot, and could damage the fuel injection system. Because of the cleansing properties of biodiesel, switching from straight diesel to a biodiesel blend can prematurely restrict the fuel filter with normal deposits in the fuel system. A fuel filter replacement might be required sooner than the recommended interval. What Fuels to Use - Canada The emission control system requires the use of diesel fuel with ultra low-sulfur (0.0015% by weight, or 15 ppm, maximum) content. Both Ultra Low Sulfur Diesel and Low Sulfur Diesel fuels are available in the United States and Ultra Low Sulfur Diesel fuel is available in Canada. At a minimum, the diesel fuel you use should meet the latest version of specification CAN/CGSB-3.517 (ULS) in Canada. In addition, the Engine Manufacturers Association (EMA) has identified properties of an improved diesel fuel for better engine performance and durability (EMA Consensus Position - Joint EMA/TMC Pump Grade Specification for Premium Diesel Fuel). Diesel fuels corresponding to the EMA description could provide better starting, less noise, and better vehicle performance. If there are questions about the fuel you are using, contact your fuel supplier. Canadian fuels are blended for seasonal changes. Diesel Type "A" fuel is blended for better cold weather starting (below 0°F or -18°C); however, you might notice some power and fuel economy loss. If Type "A" fuel is used in warmer temperatures, stalling and hard starting may occur. Diesel Type "B" fuel is blended for temperatures above 0°F (-18°C). Biodiesel Fuels It is acceptable to use diesel fuel containing up to 5% biodiesel (B5), but the final blended fuel must meet the same specification, ASTM D 975 (Grades No. 2-D or No. 1 -D S15 commonly known as Ultra Low Sulfur diesel), as other fuels used in your vehicle, and the biodiesel used for making this fuel must meet the latest version of ASTM specification D 6751. Biodiesel is produced from vegetable oils or animal fat that have been chemically modified to reduce the possibility of damage to the fuel system and engine. Higher concentration (i.e. greater than B5) biodiesel-containing fuels or the use of unmodified bio-oils blended into diesel fuel at any concentration is not recommended and could damage the fuel system and engine. Such damage would not be covered by your warranty. If there are questions about the biodiesel-containing fuels you are using, contact your fuel supplier. See your Duramax(TM) Diesel Owners Manual for additional information. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 5403 Fuel: Technical Service Bulletins Diesel Fuel System - Additive Recommendations Bulletin No.: 03-06-04-017D Date: February 20, 2007 INFORMATION Subject: Information on Diesel Fuel Additives Models: 2007 and Prior GM Light Duty and Medium Duty Trucks 2007 and Prior Isuzu Commercial Medium Duty Models with 6.5L, 6.6L, 7.2L or 7.8L Diesel Engine (VINs F, P, S, Y, 1, 2, D, 6, B, 3 - RPOs L65, L49, L56, L57, LB7, LLY, LBZ, LMM, LF8, LG4) Supercede: This bulletin is being revised to add RPO LBZ. Please discard Corporate Bulletin Number 03-06-04-017C (Section 06 - Engine/Propulsion System). The use of diesel fuel additives is not required or recommended for the 6.5L diesel or the 6.6L Duramax(R) Diesel engine under normal conditions. The filtering system is designed to block water and contaminants without the use of additives. However, some customers may desire to use fuel additives to improve the characteristics of available diesel fuels. Water Emulsifiers and Demulsifiers If the customer desires to use a fuel additive, care must be taken in its selection. There are two common methods that fuel additives use to cope with water in the fuel. One method is through demulsification of water in the fuel. This method causes water particles to combine together to form larger particles, which drop out of suspension. This allows the fuel filter/water separator to separate the water from the fuel as it is designed to. The other method of coping with water in the fuel is through emulsification. This method, often using alcohol as the emulsifier, keeps water particles suspended in the fuel. Emulsification of water in the fuel can allow water to get past the fuel filter/water separator, in most cases causing damage to the fuel system. Only alcohol free water demulsifiers should be used in General Motors diesel engines. GM Diesel Fuel Conditioner(R), P/N 88861009 (in Canada, 88861038) or both *Racor Power Shot Plus® and *Stanadyne(R) diesel fuel additives are alcohol free and utilize water demulsifiers to cope with water in the fuel. Other brands may be available in different areas; be sure that they clearly state that they are alcohol free demulsifiers before use. *We believe these sources and their products to be reliable. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. Common Diesel Fuel Concerns Fuel Waxing/Icing Fuel distributors blend # 1 and # 2 diesel fuels for seasonal requirements in a particular region. No other blending of fuels is recommended. However, a customer may desire to use a winter fuel additive to prevent fuel waxing or icing during extreme cold snaps. If a winter fuel additive is to be used, it should not contain alcohol or other water emulsifiers that may compromise the water removal effectiveness of the fuel filtering system. Bacteria and Fungi Growth Bacteria and fungi growth can occur in diesel fuel when there is water present, especially during warmer weather. The best prevention against bacteria and fungi growth is to use clean fuel that is free of water. There are diesel fuel biocides available that are designed to kill bacterial growth in the fuel system. However, the dead bacteria can still cause blockages throughout the fuel system. If bacterial growth is found in the fuel system, the proper method of removal is to flush the fuel system using Service Manual procedures, replace the fuel filter element and refill the tank with clean diesel fuel. If a customer desires to use a biocide after flushing the fuel system, it should not contain alcohol or other water emulsifiers. Low Cetane Number The cetane number is one indicator of a diesel fuel's ability to ignite. There are many indicators of overall fuel quality such as cleanliness, specific gravity, volatility, viscosity, detergency, corrosion inhibiting abilities, and lubricity. Increasing the cetane number alone is not a fix for poor quality fuel. Additionally, increasing the cetane number beyond the engine's requirements will not increase performance. However, the cetane number of diesel fuel is not always consistent and some customers may desire to use a cetane improver to ensure full performance of their engine. If such an additive is to be used, it must not contain alcohol or other water emulsifiers. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 5404 Poor Lubricity The 6.5L diesel and the 6.6L Duramax(R) Diesel engines are designed to operate on today's low sulfur fuel without the use of additives. A fuel additive designed to increase lubricity is not a fix for poor quality or contaminated fuel, but some customers may desire to use a lubricity additive to aid in the longevity of their fuel system components. If such an additive is to be used, it must not contain alcohol or other water emulsifiers. Fuel Source Issue If a vehicle is properly maintained but has fuel contamination issues, consider obtaining fuel from a different source. Purchasing fuel from a high volume fuel retailer increases the chance that the fuel is fresh and of good quality. Parts information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 5405 Fuel: Technical Service Bulletins Diesel Fuel System - Low Sulfur Fuel Information Bulletin No.: 06-06-04-041 Date: August 11, 2006 INFORMATION Subject: Information On Ultra Low Sulfur Diesel Fuel and Warning Labels Found On Fuel Station Pumps - Applicable to All Light and Medium Duty Diesel Engines with RPO codes LBZ, LB7, LH6, LLY, LMM, LL4, LQM, LQN, L49, L56, L57, L65, LG4, 1C3, 1C2, 1L5 Models Some fuel companies may be putting warning labels on their diesel fuel pumps. The warning labels will describe the sulfur content of the fuel. It will also advise customers not to use a 500 ppm sulfur fuel in a 2007 or later vehicle. Refer to the graphic illustration above. At this time, customers may find more than one type No. 2 diesel fuel available: ^ LSD (low sulfur diesel fuel) is diesel fuel with 500 ppm sulfur content. ^ ULSD (ultra low sulfur diesel fuel) has a sulfur content of 15 ppm or lower. ^ Off Road Fuel with a 500 ppm or higher sulfur content Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 5406 All fuel companies will start transitions to ULSD (15 ppm sulfur max) in mid-2006. Refineries in the U.S. and Canada are required to start producing ULSD on June 1. U.S. and Canadian supply terminals must be converted to ULSD by September 1 and retail stations must be converted by October 15. In the U.S., both LSD (500 ppm sulfur) and ULSD (15 ppm sulfur) will be available. However, the EPA's own pre-compliance reports indicate that 95% of on-road diesel fuel will meet the 15 ppm standard on a nationwide basis. All LSD (500 ppm sulfur) and Off Road Fuels (greater than 500 ppm sulfur) must be segregated and clearly marked. In Canada, only 15 ppm on-road diesel fuel will be available nationwide by October 15th. Below is a description of GM vehicles and proper fuel usage: In January of 2007, a new 6.6L Duramax(TM) Diesel (RPO LMM-eighth digit of the VIN is a 6) will be released. This 6.6 LMM engine must use the ULSD (ultra low sulfur diesel) fuel. The 2007 LMM diesel equipped vehicles will require the use of ULSD for proper operation of the emission control system. These vehicles will be labeled "ULSD Required". The vehicles will be labeled in two locations (per regulation) near the fuel filler and on the IP. The Owner's Manual and diesel supplement will have several instances/sections that define proper fuel use. Important: Off Road Fuels should not be used in any General Motors highway use vehicles. All other Light and Medium Duty 6.2L, 6.5L, and 6.6L RPO codes LB7, LBZ, and LLY diesel engines (including 2007 model year LBZ and LLY) can use either the LSF (low sulfur diesel) or ULSF (ultra low sulfur) diesel fuels. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 5407 Fuel: Specifications WHAT FUEL TO USE IN THE U.S. In the United States, for best results use Number 2-D diesel fuel year-round (above and below freezing conditions) as oil companies blend Number 2-D fuel to address climate differences. Number 1-D diesel fuel may be used in very cold temperatures (when it stays below 0°F or -18°C); however, it will produce a power and fuel economy loss. Avoid the use of Number 1-D diesel fuel in warm or hot climates. It may result in stalling, poor starting when the engine is hot and may damage the fuel injection system. At a minimum, the diesel fuel you use should meet specifications ASTM D975-02 (Grade Low Sulfur) in the United States. In addition, the Engine Manufacturers Association (EMA) has identified properties of an improved diesel fuel for better engine performance and durability. Diesel fuels corresponding to the EMA Recommended Guideline on Premium Diesel Fuel (FQP-1A) could provide better starting, less noise and better vehicle performance. If there are questions about the fuel you are using, contact your fuel supplier. It is acceptable to use diesel fuel containing up to 5% biodiesel (B5), but the final blended fuel must meet the same specification, ASTM D975-02 (Grade Low Sulfur), as other fuels used in your vehicle, and the biodiesel used for making this fuel must meet the ASTM D6751-02 specification. Biodiesel is produced from vegetable oils or animal fat that have been chemically modified to reduce the possibility of damage to your fuel system and engine. Higher concentration (i.e., greater than B5) biodiesel-containing fuels or the use of unmodified bio-oils blended into diesel fuel at any concentration is not recommended and could damage your fuel system and engine. Such damage would not be covered by your warranty. If there are questions about the biodiesel-containing fuels you are using, contact your fuel supplier. Diesel fuel may foam when you fill your tank. This can cause the automatic pump nozzle to shut off, even though your tank is not full. If this happens, just wait for the foaming to stop and then continue to fill your tank. CAUTION: Heat coming from the engine may cause the fuel to expand and force the fuel out of your tank. If something ignites the fuel, a fire could start and people could be burned. To help avoid this, fill your fuel tank only until the automatic nozzle shuts off. Do not try to "top it off." WHAT FUEL TO USE IN CANADA Canadian fuels are blended for seasonal changes. Diesel Type "A" fuel is blended for better cold weather starting (below 0°F or -18°C); however, you may notice some power and fuel economy loss. If Type "A" fuel is used in warmer temperatures, stalling and hard starting may occur. Diesel Type "B" fuel is blended for temperatures above 0°F (-18°C). The emission control system requires the use of diesel fuel with low-sulfur (0.05% by weight) content. Both low- and higher-sulfur fuels will be available in Canada. Only low-sulfur diesel fuels are available in the United States. It is important that diesel-powered trucks are refueled only with low-sulfur fuel. Use of fuels with higher-sulfur content will affect the function of the emission components and may cause reduced performance, excessive smoke and unpleasant odor. At a minimum, the diesel fuel you use should meet specifications CAN/CGSB-3.517-2000 (Low Sulfur Diesel) in Canada. In addition, the Engine Manufacturers Association (EMA) has identified properties of an improved diesel fuel for better engine performance and durability (FQP-1A). Diesel fuels corresponding to the EMA description could provide better starting, less noise and better vehicle performance. If there are questions about the fuel you are using, contact your fuel supplier. It is acceptable to use diesel fuel containing up to 5% biodiesel (B5), but the final blended fuel must meet the same specification, CAN/CGSB--3.517-2000 (Low Sulfur Diesel) in Canada, as other fuels used in your vehicle, and the biodiesel used for making this fuel must meet the ASTM D6751-02 specification. Biodiesel is produced from vegetable oils or animal fat that have been chemically modified to reduce the possibility of damage to your fuel system and engine. Higher concentration (i.e., greater than B5) biodiesel-containing fuels or the use of unmodified bio-oils blended into diesel fuel at any concentration is not recommended and could damage your fuel system and engine. Such damage would not be covered by your warranty. If there are questions about the biodiesel-containing fuels you are using, contact your fuel supplier. WATER IN FUEL CAUTION: Diesel fuel containing water is still flammable. You could be burned. If you ever try to drain water from your fuel, keep sparks, flames and smoking materials away from the mixture. NOTICE: If there is water in your diesel fuel and the weather is warm or humid, fungus and bacteria can grow in the fuel. They can damage your fuel system. A diesel fuel biocide can be used to sterilize your fuel system. However, your fuel system may still need to be cleaned. If your fuel tank needs to be purged to remove water. Improper purging can damage your fuel system. Sometimes, water can be pumped into your fuel tank along with your diesel fuel. This can happen if a service station doesn't regularly inspect and clean its fuel tanks, or if it gets contaminated fuel from its suppliers. If this happens, a "WATER IN FUEL" message will appear on the Driver Information Center (DIC). If it does, the water must be drained. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 5408 Fuel: Testing and Inspection CONTAMINANTS-IN-FUEL DIAGNOSIS Fungi and other microorganisms can survive and multiply in diesel fuel if water is present. The fungi can be present in any part of the fuel handling system. These fungi grow into long strings and will form into large globules. The growths appear slimy and are usually black, green, or brown. The fungi may grow anywhere in the fuel but are most plentiful where diesel fuel and water meet. As the fuel is agitated, when service station tanks are being filled, fungi are distributed throughout the tank and may be pumped into a vehicle. Fungi use the fuel as their main energy supply and need only trace amounts of water and minerals. As they grow and multiply, they change fuel into water, sludge, acids, and products of metabolism. The most common symptom is fuel filter plugging, however various metal fuel system components including fuel sender assembly, pipes, fuel injectors, and fuel injection pump can corrode. CAUTION: Avoid physical contact with the biocides in order to avoid personal injury. If fungi have caused fuel system contamination, use a diesel fuel biocide to sterilize the fuel system. Do not exceed the dosage recommended on the label. Discontinue the use of a biocide when towing a trailer. It is permissible to have biocide in the fuel when starting to tow, but do not add any biocide while towing. Steam cleaning may be necessary if most of the fungus growth cannot be removed with biocides. The presence of water or gasoline in diesel fuel may also cause injection pump and fuel injector damage. This procedure checks for the presence of water and gasoline in diesel fuel that may cause fuel injection pump and fuel injector damage. Remove and inspect the fuel filter. - If water, gasoline or fungi/bacteria are not present, end the inspection. - If water or fungi/bacteria are present, go to Cleaning Water from the Fuel System. Refer to Fuel System Cleaning. - If gasoline is present, go to Cleaning Gasoline from the Fuel System. Refer to Fuel System Cleaning. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Cooler > Component Information > Description and Operation Fuel Cooler: Description and Operation FUEL SYSTEM COOLER The fuel system cooler (1) is located in front of the primary fuel tank. The fuel system cooler cools the fuel before it is returned to the fuel tank. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Cooler > Component Information > Service and Repair > Pickup Fuel Cooler: Service and Repair Pickup FUEL SYSTEM COOLER REPLACEMENT (PICKUP) REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the fuel lines at the cooler (1). 3. Remove the fuel cooler bolts (4, 6). 4. Remove the fuel cooler (1). 5. Remove the fuel cooler support bracket bolt (2, 5), and bracket (3) from the fuel cooler (1), if necessary. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the fuel cooler support bracket (3), and bolts (2, 5) to the fuel cooler (1), if necessary. Tighten Tighten the bolts to 18 N.m (13 lb ft). 2. Install the fuel cooler (1) to the chassis and crossover. 3. Install the fuel cooler bolts (4, 6). Tighten Tighten the bolts to 18 N.m (13 lb ft). 4. Connect the fuel lines at the fuel cooler (1). 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Cooler > Component Information > Service and Repair > Pickup > Page 5414 6. Prime the fuel system. Refer to Fuel System Priming. 7. Start the engine. If the engine stalls, repeat the above step. 8. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Cooler > Component Information > Service and Repair > Pickup > Page 5415 Fuel Cooler: Service and Repair Cab/Chassis FUEL SYSTEM COOLER REPLACEMENT (CAB/CHASSIS) REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the fuel lines at the fuel cooler (1). 3. Remove the fuel cooler nuts (2). 4. Remove the fuel cooler (1). INSTALLATION PROCEDURE 1. Install the fuel cooler (1). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel cooler nuts (2). Tighten Tighten the nuts to 40 N.m (30 lb ft). 3. Connect the fuel lines at the fuel cooler (1). 4. Lower the vehicle. 5. Prime the fuel system. Refer to Fuel System Priming. 6. Start the engine. If the engine stalls, repeat the above step. 7. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 05-06-04-043A > Aug > 05 > Fuel System/Body - Fuel Filler Cap Tether Too Short Fuel Filler Cap: Customer Interest Fuel System/Body - Fuel Filler Cap Tether Too Short Bulletin No.: 05-06-04-043A Date: August 02, 2005 TECHNICAL Subject: Fuel Cap Tether Too Short to Hook On Fuel Door While Fueling Vehicle (Install Fuel Filler Housing and Cap) Models: 2004-2005 Cadillac Escalade Models 2004-2005 Chevrolet Silverado, Suburban, Tahoe Models 2004-2005 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to correct the fuel filler cap P/N. P/N 15225006 is released for 2006 and 2007 model year vehicles only. The correct fuel cap for the 2004 and 2005 model year is P/N 15225005. Dealers who currently have P/N 15225006 on order (possibly back-ordered) for this concern should cancel their order and re-order P/N 15225005. Please discard Corporate Bulletin Number 05-06-04-043 (Section 06 - Engine/Propulsion System). Built Prior to the VIN Breakpoints shown. Condition Some customers may comment that the fuel cap tether is too short to hook on the fuel door while fueling the vehicle. Cause The existing fuel cap tether is too short. The existing fuel filler housing elongated hole is too small to accommodate the new fuel cap tether. Correction Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 05-06-04-043A > Aug > 05 > Fuel System/Body - Fuel Filler Cap Tether Too Short > Page 5424 Important: Clean the fuel filler cap and surrounding areas prior to removing the fuel filler housing in order to avoid possible contamination. 1. Remove the fuel fill cap. 2. Remove the fuel tank filler housing to fuel tank fill pipe screws. 3. Remove the fuel tank filler housing to body TORX® screws (1) and retainer (2). Important: It is NOT necessary to raise the vehicle in order to remove and/or install the fuel filler housing. 4. Remove the fuel filler housing from under the vehicle. 5. Install the new fuel filler housing, P/N 15289921, from under the vehicle. 6. Install the fuel tank filler housing to fuel tank fill pipe screws. Tighten Tighten the screws to 2.3 N.m (20 lb in). 7. Install the fuel tank filler housing to body TORX(R) screws and retainer. Tighten Tighten the screws to 2.3 N.m (20 lb in). Important: The new fuel cap, P/N 15225005 "tether strap" installs in the elongated hole in the fuel filler housing. DO NOT install the new fuel cap tether in the round hole in the fuel filler housing. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 05-06-04-043A > Aug > 05 > Fuel System/Body - Fuel Filler Cap Tether Too Short > Page 5425 8. Install the new fuel cap, P/N 15225005, tether strap in the elongated hole in the fuel filler housing. 9. Install the fuel fill cap on the filler pipe and tighten until the cap clicks. Parts Information Warranty Information For vehicles repaired under warranty, use the table Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 05-06-04-043A > Aug > 05 > Fuel System/Body - Fuel Filler Cap Tether Too Short Fuel Filler Cap: All Technical Service Bulletins Fuel System/Body - Fuel Filler Cap Tether Too Short Bulletin No.: 05-06-04-043A Date: August 02, 2005 TECHNICAL Subject: Fuel Cap Tether Too Short to Hook On Fuel Door While Fueling Vehicle (Install Fuel Filler Housing and Cap) Models: 2004-2005 Cadillac Escalade Models 2004-2005 Chevrolet Silverado, Suburban, Tahoe Models 2004-2005 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to correct the fuel filler cap P/N. P/N 15225006 is released for 2006 and 2007 model year vehicles only. The correct fuel cap for the 2004 and 2005 model year is P/N 15225005. Dealers who currently have P/N 15225006 on order (possibly back-ordered) for this concern should cancel their order and re-order P/N 15225005. Please discard Corporate Bulletin Number 05-06-04-043 (Section 06 - Engine/Propulsion System). Built Prior to the VIN Breakpoints shown. Condition Some customers may comment that the fuel cap tether is too short to hook on the fuel door while fueling the vehicle. Cause The existing fuel cap tether is too short. The existing fuel filler housing elongated hole is too small to accommodate the new fuel cap tether. Correction Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 05-06-04-043A > Aug > 05 > Fuel System/Body - Fuel Filler Cap Tether Too Short > Page 5431 Important: Clean the fuel filler cap and surrounding areas prior to removing the fuel filler housing in order to avoid possible contamination. 1. Remove the fuel fill cap. 2. Remove the fuel tank filler housing to fuel tank fill pipe screws. 3. Remove the fuel tank filler housing to body TORX® screws (1) and retainer (2). Important: It is NOT necessary to raise the vehicle in order to remove and/or install the fuel filler housing. 4. Remove the fuel filler housing from under the vehicle. 5. Install the new fuel filler housing, P/N 15289921, from under the vehicle. 6. Install the fuel tank filler housing to fuel tank fill pipe screws. Tighten Tighten the screws to 2.3 N.m (20 lb in). 7. Install the fuel tank filler housing to body TORX(R) screws and retainer. Tighten Tighten the screws to 2.3 N.m (20 lb in). Important: The new fuel cap, P/N 15225005 "tether strap" installs in the elongated hole in the fuel filler housing. DO NOT install the new fuel cap tether in the round hole in the fuel filler housing. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 05-06-04-043A > Aug > 05 > Fuel System/Body - Fuel Filler Cap Tether Too Short > Page 5432 8. Install the new fuel cap, P/N 15225005, tether strap in the elongated hole in the fuel filler housing. 9. Install the fuel fill cap on the filler pipe and tighten until the cap clicks. Parts Information Warranty Information For vehicles repaired under warranty, use the table Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Page 5433 Fuel Filler Cap: Description and Operation FUEL FILLER CAP The fuel filler cap has a torque-limiting device that prevents the cap from being over tightened. To install, turn the cap clockwise until you hear audible clicks. This indicates that the cap is fully seated. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Improved Fuel Filter Design Fuel Filter: Technical Service Bulletins Fuel System - Improved Fuel Filter Design INFORMATION Bulletin No.: 04-06-04-070B Date: March 02, 2009 Subject: Information on Improved Fuel Filter for 6.6L Duramax(TM) Diesel Engine Models: 2001-2009 Chevrolet Silverado 2003-2009 Chevrolet Kodiak 2006-2009 Chevrolet Express 2001-2009 GMC Sierra 2003-2009 GMC TopKick 2006-2009 GMC Sierra Equipped with 6.6L Duramax(TM) Diesel Engine (VINs 1, 2, D, 6 - RPOs LB7, LLY, LBZ, LMM) Supercede: This bulletin is being revised to provide additional information to the field on fuel filter applications for the Duramax diesel engine. Please discard Corporate Bulletin Number 04-06-04-070A (Section 06 - Engine/Propulsion System). Important: It is acceptable to use diesel fuel containing up to 5% biodiesel (B5). Higher concentration (i.e., greater than B5) biodiesel-containing fuels or the use of unmodified bio-oils blended into diesel fuel at any concentration is not recommended and could damage the fuel system and engine. Such damage would not be covered by your warranty. A revised fuel filter is released that will service all 2001-2009 Chevrolet and GMC C/K models and 2003-2009 Chevrolet and GMC C4500/5500 Series vehicles with the 6.6L Duramax(TM) Diesel. The new coalescer filter provides the following benefits / improvements over the existing dual pleat design: ^ 150-200% increase in service life, depending on contaminant type Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Improved Fuel Filter Design > Page 5438 ^ Improved fuel system protection with some premium diesel and B5 biodiesel blends ^ Equivalent coarse water droplet removal efficiency of previous design ^ Greatly improved removal of emulsified water - a major contributor to fuel system issues Proper fuel filter servicing and the use of clean diesel fuel that is free of water or contaminants are critical for the longevity of fuel system components of a modern direct injected diesel engine. Adherence to the fuel filter change interval will help to ensure that the Duramax fuel system will be protected from contaminants and that the engine will continue to operate as designed. Purchasing fuel from a high volume fuel retailer increases the chances that the fuel is fresh and of good quality. Parts Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Page 5439 Fuel Filter: Locations FUEL FILTER/HEATER ELEMENT HOUSING Fuel Filter/Heater Element Housing Water In Fuel Sensor The Fuel Filter/Heater Element Housing is located on the right engine rocker cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Page 5440 Fuel Filter: Description and Operation FUEL FILTER The fuel filter is located on the rocker cover. The paper filter element traps particles in the fuel that may damage the fuel injection system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly Fuel Filter: Service and Repair Fuel Filter Assembly FUEL FILTER ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Drain the fuel from the fuel filter. Refer to Water-in-Fuel Draining Procedure. 2. Reposition the fuel hose clamps. 3. Remove the fuel hoses. 4. Disconnect the fuel filter electrical connectors. 5. Remove the fuel filter bracket bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 5443 6. Remove the fuel filter assembly. 7. Remove the fuel filter bracket bolts and bracket from the fuel filter/heater element housing. 8. Remove the fuel filter from the fuel filter/heater element housing. 9. Inspect the fuel filter, replace if necessary. INSTALLATION PROCEDURE 1. Install the fuel filter to the fuel filter/heater element housing. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel filter bracket and bolts to the fuel filter/heater element housing. Tighten Tighten the bolts to 20 N.m (15 lb ft). 3. Install the fuel filter assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 5444 4. Install the fuel filter bracket bolts. Tighten Tighten the bolts to 20 N.m (15 lb ft). 5. Connect the fuel filter electrical connectors. 6. Install the fuel hoses. 7. Position the fuel hose clamps. 8. Prime the fuel system. Refer to Fuel System Priming. 9. Start the engine. If the engine stalls, repeat the above step. 10. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 5445 Fuel Filter: Service and Repair Fuel Filter Element FUEL FILTER REPLACEMENT REMOVAL PROCEDURE 1. Drain the fuel from the fuel filter. Refer to Water-in-Fuel Draining Procedure. 2. Reposition the fuel hose clamps. 3. Remove the fuel hoses. 4. Disconnect the fuel filter connectors. 5. Unscrew the fuel filter from the fuel filter adapter. 6. Remove the water-in-fuel sensor from the fuel filter. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 5446 1. Install the water-in-fuel sensor to the NEW fuel filter. IMPORTANT: Inspect the fuel heater element housing for contamination. Contamination on the fuel heater element housing may cause leakage at the fuel filter. Coat the fuel filter seal with clean engine oil. 2. Screw on the NEW fuel filter to the fuel filter adapter. 3. Connect the fuel filter connectors. 4. Install the fuel hoses. 5. Position the fuel hose clamps. 6. Prime the fuel system. Refer to Fuel System Priming. 7. Start the engine. If the engine stalls, repeat the above step. 8. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 5447 Fuel Filter: Service and Repair Fuel Filter Life Reset FUEL FILTER LIFE RESET This message will appear when a reset is performed either by using the steering wheel controls or the following manual procedure. For vehicles with steering wheel controls: 1. Reset the fuel filter monitor. 2. Press and hold the select button for five seconds while the "FUEL FILTER LIFE" message is displayed. This message will appear on the DIC for ten seconds. For vehicles without steering wheel controls, do the following: 1. Without pressing the pedals, turn the ignition key to the "ON" position without starting the engine. 2. Wait five seconds. 3. Completely press the brake and the accelerator pedals simultaneously and hold for ten seconds. The system is now reset. 4. Turn the ignition key off. The next time the engine is started, the message will no longer be displayed. Always reset the FUEL FILTER LIFE system after a fuel filter change. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 5448 Fuel Filter: Service and Repair Fuel System Priming FUEL SYSTEM PRIMING IMPORTANT: In order for the DURAMAX diesel engine fuel system to work properly, the fuel lines must be full of fuel and contain no air. If air gets into the fuel lines, it will be necessary to prime the fuel system to eliminate the air before operating the vehicle. Air could have entered to system in one of the following ways: - The vehicle ran out of fuel. - The filter was removed for service or replacement. - The fuel lines were removed or disconnected for servicing. - The fuel filter water drain cock was opened while the engine was running. If one or more of the above occurred, air has entered the fuel system and you will need to prime the system prior to operating the vehicle. 1. Prior to priming the engine, ensure that the following is complete: - There is fuel in the fuel tank. - The fuel filter has been installed and properly tightened. - The fuel lines are properly connected. - The fuel filter is cool to the touch. - Any dirt or debris is removed from the fuel filter head and vent valve. 2. Open the vent valve by turning the screw counterclockwise several full turns. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Fuel Filter Assembly > Page 5449 3. Operate the priming pump until a small amount of fuel seeps from the vent valve. allow the pump to return upwards between pumps. When fuel is present, the filter is full of fuel and the system should be primed. 4. Close the vent valve. 5. Clean any fuel which accumulated on the fuel filter. 6. Start the engine and allow it to idle for a few minutes. 7. Check the filter for leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter Life Indicator <--> [Fuel Filter Restriction Warning Indicator] > Component Information > Service and Repair Fuel Filter Life Indicator: Service and Repair FUEL FILTER LIFE RESET This message will appear when a reset is performed either by using the steering wheel controls or the following manual procedure. For vehicles with steering wheel controls: 1. Reset the fuel filter monitor. 2. Press and hold the select button for five seconds while the "FUEL FILTER LIFE" message is displayed. This message will appear on the DIC for ten seconds. For vehicles without steering wheel controls, do the following: 1. Without pressing the pedals, turn the ignition key to the "ON" position without starting the engine. 2. Wait five seconds. 3. Completely press the brake and the accelerator pedals simultaneously and hold for ten seconds. The system is now reset. 4. Turn the ignition key off. The next time the engine is started, the message will no longer be displayed. Always reset the FUEL FILTER LIFE system after a fuel filter change. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Page 5456 Fuel Heater Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Service and Repair > Fuel Filter/Heater Element Housing Replacement Fuel Heater: Service and Repair Fuel Filter/Heater Element Housing Replacement FUEL FILTER/HEATER ELEMENT HOUSING REPLACEMENT REMOVAL PROCEDURE 1. Drain the fuel from the fuel filter. Refer to Water-in-Fuel Draining Procedure. 2. Reposition the fuel hose clamps. 3. Remove the fuel hoses. 4. Disconnect the fuel filter electrical connectors. 5. Remove the fuel filter bracket bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Service and Repair > Fuel Filter/Heater Element Housing Replacement > Page 5459 6. Remove the fuel filter assembly. 7. Remove the fuel filter bracket bolts and bracket from the fuel filter/heater element housing. 8. Remove the fuel filter from the fuel filter/heater element housing. 9. Inspect the fuel filter, replace if necessary. INSTALLATION PROCEDURE 1. Install the fuel filter to the fuel filter/heater element housing. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel filter bracket and bolts to the fuel filter/heater element housing. Tighten Tighten the bolts to 20 N.m (15 lb ft). 3. Install the fuel filter assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Service and Repair > Fuel Filter/Heater Element Housing Replacement > Page 5460 4. Install the fuel filter bracket bolts. Tighten Tighten the bolts to 20 N.m (15 lb ft). 5. Connect the fuel filter electrical connectors. 6. Install the fuel hoses. 7. Position the fuel hose clamps. 8. Prime the fuel system. Refer to Fuel System Priming. 9. Start the engine. If the engine stalls, repeat the above step. 10. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Line > Component Information > Technical Service Bulletins > Fuel System - Fuel Injection Line Fitting Sealant Usage Fuel Injector Line: Technical Service Bulletins Fuel System - Fuel Injection Line Fitting Sealant Usage Bulletin No.: 06-06-04-060 Date: November 06, 2006 SERVICE MANUAL UPDATE Subject: Discontinue Use of Sealer on Fuel Injection Line Fittings Models: 2001-2007 Chevrolet Silverado 2003-2007 Chevrolet Kodiak 2001-2007 GMC Sierra 2003-2007 GMC TopKick with 6.6L Duramax(TM) Diesel Engine (VIN 2 - RPO LLY) This bulletin is being issued to revise various procedures involving fuel injection line fittings in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Be advised that the recommendation to apply a sealer on fuel injection line fittings has been discontinued. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest for Fuel Injector Wiring Harness: > 05-06-04-047C > Apr > 08 > Fuel System - Reduced Power/MIL ON/Multiple DTCs Set Fuel Injector Wiring Harness: Customer Interest Fuel System - Reduced Power/MIL ON/Multiple DTCs Set TECHNICAL Bulletin No.: 05-06-04-047C Date: April 23, 2008 Subject: Service Engine Soon (SES) Light On with Reduction in Engine Power, DTCs P0202 and P2149 or P0207 and P2146 or P1294 Set (Install Revised 90 Degree Injector Connector with Harness Support Bracket Service Kit) Models: 2004-2005 Chevrolet Silverado 2004-2005 Chevrolet Kodiak C4500/C5500 Series 2004-2005 GMC Sierra 2004-2005 GMC Topkick C4500/C5500 Series with 6.6L Duramax(TM) Diesel Engine (VIN 2 - RPO LLY) Supercede: This bulletin is being revised to add DTC P1294 to Subject Line and Condition Statement. Please discard Corporate Bulletin Number 05-06-04-047B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on the Service Engine Soon light becoming illuminated along with a severe reduction in engine power (limp home mode). Upon investigation, the technician may find DTCs P0202 and P2149 or P0207 and P2146 or P1294. Cause The injector connector circuits on cylinders 2 and 7 are not fully supported near the connector and are more susceptible to terminal breakage from engine vibration. Correction If published diagnostics lead to an injector connector install the revised 90 degree connector and the harness support bracket from the service kit P/N 98017958 using the following repair procedures. Repair Procedure for Left Bank Cylinder Number 2 1. Disconnect the negative battery cables. Refer to Service Information (SI) for the Battery Negative Cable Disconnect/Connect Procedure (Single Battery) and Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery). 2. Remove the left wheelhouse panel. Refer to Service Information (SI) for the Wheelhouse Panel Replacement. 3. Remove the left charge air cooler inlet pipe. Refer to Service Information (SI) for the Charged Air Cooler Hoses/Pipes Replacement (Left). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest for Fuel Injector Wiring Harness: > 05-06-04-047C > Apr > 08 > Fuel System - Reduced Power/MIL ON/Multiple DTCs Set > Page 5474 4. Disconnect cylinder number 2 and cylinder number 4 fuel injector harness connectors. 5. Remove the cylinder number 2 glow plug connector nut and remove the cylinder number 2 glow plug harness connector from the glow plug. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest for Fuel Injector Wiring Harness: > 05-06-04-047C > Apr > 08 > Fuel System - Reduced Power/MIL ON/Multiple DTCs Set > Page 5475 6. Remove the fuel injector harness bracket bolt. 7. Cut the tape to remove the fuel injector harness bracket and discard the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest for Fuel Injector Wiring Harness: > 05-06-04-047C > Apr > 08 > Fuel System - Reduced Power/MIL ON/Multiple DTCs Set > Page 5476 8. Cut cylinder number 2 fuel injector connector off the engine harness approximately 38.1 mm (1.5 in) away from the base of the connector. Important: It is not necessary to maintain the same polarization of the injector circuits. 9. Strip approximately 1/4 inch of insulation from both fuel injector circuits and using the supplied Duraseal(R) connectors crimp the new 90 degree fuel injector connector to the engine harness. 10. Use an Ultra Torch or equivalent to shrink the tubing and set the glue in the Duraseal(R) connectors. 11. Secure the Duraseal® connectors with electrical tape. 12. Position the new injector harness bracket to align with the bracket bolt hole and secure to the harness with electrical tape. 13. Install the new injector harness bracket and original bolt. Tighten Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest for Fuel Injector Wiring Harness: > 05-06-04-047C > Apr > 08 > Fuel System - Reduced Power/MIL ON/Multiple DTCs Set > Page 5477 Tighten the fuel injector harness bracket bolt to 10 N.m (89 lb in). 14. Install the cylinder number 2 glow plug harness connector and nut. Tighten Tighten the glow plug harness connector nut to 2 N.m (18 lb in). 15. Connect the cylinder number 2 and cylinder number 4 fuel injector harness connectors. 16. Install the left charge air cooler inlet pipe. Refer to Service Information (SI) for the Charged Air Cooler Hoses/Pipes Replacement (Left). 17. Install the left wheelhouse panel. Refer to Service Information (SI) for the Wheelhouse Panel Replacement. Repair Procedure for Right Bank Cylinder Number 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest for Fuel Injector Wiring Harness: > 05-06-04-047C > Apr > 08 > Fuel System - Reduced Power/MIL ON/Multiple DTCs Set > Page 5478 1. Remove the fuel filter assembly bolts. 2. Position the fuel filter assembly out of the way. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest for Fuel Injector Wiring Harness: > 05-06-04-047C > Apr > 08 > Fuel System - Reduced Power/MIL ON/Multiple DTCs Set > Page 5479 3. Disconnect cylinder number 7 fuel injector harness connector and cut the number 7 fuel injector harness connector wires directly at the base of the connector. Important: It is not necessary to maintain the same polarization of the injector circuits. 4. Strip approximately 1/4 inch of insulation from both fuel injector circuits and using the supplied Duraseal(R) connectors crimp the new 90 degree fuel injector connector to the engine harness. 5. Use an Ultra Torch or equivalent to shrink the tubing and set the glue in the Duraseal(R) connectors. 6. Secure the Duraseal® connectors with electrical tape. 7. Install the new injector harness bracket to the upper valve cover. 8. Install the injector harness bracket bolts supplied with the kit. Tighten Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest for Fuel Injector Wiring Harness: > 05-06-04-047C > Apr > 08 > Fuel System - Reduced Power/MIL ON/Multiple DTCs Set > Page 5480 Tighten the injector harness bracket bolts to 20 N.m (15 lb ft). 9. Connect the cylinder number 7 injector harness connector. 10. Install the injector harness to the bracket as shown. 11. Install the fuel filter assembly. 12. Install the fuel filter assembly bolts. Tighten Tighten the fuel filter assembly bolts to 20 N.m (15 lb ft). 13. Connect the negative battery cables. Refer to Service Information (SI) for the Battery Negative Cable Disconnect/Connect Procedure (Single Battery) and Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest for Fuel Injector Wiring Harness: > 05-06-04-047C > Apr > 08 > Fuel System - Reduced Power/MIL ON/Multiple DTCs Set > Page 5481 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector Wiring Harness: > 05-06-04-047C > Apr > 08 > Fuel System - Reduced Power/MIL ON/Multiple DTCs Set Fuel Injector Wiring Harness: All Technical Service Bulletins Fuel System - Reduced Power/MIL ON/Multiple DTCs Set TECHNICAL Bulletin No.: 05-06-04-047C Date: April 23, 2008 Subject: Service Engine Soon (SES) Light On with Reduction in Engine Power, DTCs P0202 and P2149 or P0207 and P2146 or P1294 Set (Install Revised 90 Degree Injector Connector with Harness Support Bracket Service Kit) Models: 2004-2005 Chevrolet Silverado 2004-2005 Chevrolet Kodiak C4500/C5500 Series 2004-2005 GMC Sierra 2004-2005 GMC Topkick C4500/C5500 Series with 6.6L Duramax(TM) Diesel Engine (VIN 2 - RPO LLY) Supercede: This bulletin is being revised to add DTC P1294 to Subject Line and Condition Statement. Please discard Corporate Bulletin Number 05-06-04-047B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on the Service Engine Soon light becoming illuminated along with a severe reduction in engine power (limp home mode). Upon investigation, the technician may find DTCs P0202 and P2149 or P0207 and P2146 or P1294. Cause The injector connector circuits on cylinders 2 and 7 are not fully supported near the connector and are more susceptible to terminal breakage from engine vibration. Correction If published diagnostics lead to an injector connector install the revised 90 degree connector and the harness support bracket from the service kit P/N 98017958 using the following repair procedures. Repair Procedure for Left Bank Cylinder Number 2 1. Disconnect the negative battery cables. Refer to Service Information (SI) for the Battery Negative Cable Disconnect/Connect Procedure (Single Battery) and Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery). 2. Remove the left wheelhouse panel. Refer to Service Information (SI) for the Wheelhouse Panel Replacement. 3. Remove the left charge air cooler inlet pipe. Refer to Service Information (SI) for the Charged Air Cooler Hoses/Pipes Replacement (Left). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector Wiring Harness: > 05-06-04-047C > Apr > 08 > Fuel System - Reduced Power/MIL ON/Multiple DTCs Set > Page 5487 4. Disconnect cylinder number 2 and cylinder number 4 fuel injector harness connectors. 5. Remove the cylinder number 2 glow plug connector nut and remove the cylinder number 2 glow plug harness connector from the glow plug. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector Wiring Harness: > 05-06-04-047C > Apr > 08 > Fuel System - Reduced Power/MIL ON/Multiple DTCs Set > Page 5488 6. Remove the fuel injector harness bracket bolt. 7. Cut the tape to remove the fuel injector harness bracket and discard the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector Wiring Harness: > 05-06-04-047C > Apr > 08 > Fuel System - Reduced Power/MIL ON/Multiple DTCs Set > Page 5489 8. Cut cylinder number 2 fuel injector connector off the engine harness approximately 38.1 mm (1.5 in) away from the base of the connector. Important: It is not necessary to maintain the same polarization of the injector circuits. 9. Strip approximately 1/4 inch of insulation from both fuel injector circuits and using the supplied Duraseal(R) connectors crimp the new 90 degree fuel injector connector to the engine harness. 10. Use an Ultra Torch or equivalent to shrink the tubing and set the glue in the Duraseal(R) connectors. 11. Secure the Duraseal® connectors with electrical tape. 12. Position the new injector harness bracket to align with the bracket bolt hole and secure to the harness with electrical tape. 13. Install the new injector harness bracket and original bolt. Tighten Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector Wiring Harness: > 05-06-04-047C > Apr > 08 > Fuel System - Reduced Power/MIL ON/Multiple DTCs Set > Page 5490 Tighten the fuel injector harness bracket bolt to 10 N.m (89 lb in). 14. Install the cylinder number 2 glow plug harness connector and nut. Tighten Tighten the glow plug harness connector nut to 2 N.m (18 lb in). 15. Connect the cylinder number 2 and cylinder number 4 fuel injector harness connectors. 16. Install the left charge air cooler inlet pipe. Refer to Service Information (SI) for the Charged Air Cooler Hoses/Pipes Replacement (Left). 17. Install the left wheelhouse panel. Refer to Service Information (SI) for the Wheelhouse Panel Replacement. Repair Procedure for Right Bank Cylinder Number 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector Wiring Harness: > 05-06-04-047C > Apr > 08 > Fuel System - Reduced Power/MIL ON/Multiple DTCs Set > Page 5491 1. Remove the fuel filter assembly bolts. 2. Position the fuel filter assembly out of the way. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector Wiring Harness: > 05-06-04-047C > Apr > 08 > Fuel System - Reduced Power/MIL ON/Multiple DTCs Set > Page 5492 3. Disconnect cylinder number 7 fuel injector harness connector and cut the number 7 fuel injector harness connector wires directly at the base of the connector. Important: It is not necessary to maintain the same polarization of the injector circuits. 4. Strip approximately 1/4 inch of insulation from both fuel injector circuits and using the supplied Duraseal(R) connectors crimp the new 90 degree fuel injector connector to the engine harness. 5. Use an Ultra Torch or equivalent to shrink the tubing and set the glue in the Duraseal(R) connectors. 6. Secure the Duraseal® connectors with electrical tape. 7. Install the new injector harness bracket to the upper valve cover. 8. Install the injector harness bracket bolts supplied with the kit. Tighten Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector Wiring Harness: > 05-06-04-047C > Apr > 08 > Fuel System - Reduced Power/MIL ON/Multiple DTCs Set > Page 5493 Tighten the injector harness bracket bolts to 20 N.m (15 lb ft). 9. Connect the cylinder number 7 injector harness connector. 10. Install the injector harness to the bracket as shown. 11. Install the fuel filter assembly. 12. Install the fuel filter assembly bolts. Tighten Tighten the fuel filter assembly bolts to 20 N.m (15 lb ft). 13. Connect the negative battery cables. Refer to Service Information (SI) for the Battery Negative Cable Disconnect/Connect Procedure (Single Battery) and Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector Wiring Harness: > 05-06-04-047C > Apr > 08 > Fuel System - Reduced Power/MIL ON/Multiple DTCs Set > Page 5494 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Control Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel Injector Control Module: > 09-06-04-034 > Aug > 09 > Fuel System - Reduced Engine Power, MIL (Various Codes) Fuel Injector Control Module: Customer Interest Fuel System - Reduced Engine Power, MIL (Various Codes) TECHNICAL Bulletin No.: 09-06-04-034 Date: August 17, 2009 Subject: Malfunction Indicator Lamp (MIL) Illuminated, Fuel Injector Driver Circuit DTCs P0201, P0202, P0203, P0204, P0205, P0206, P0207, P0208 and Cylinder Bank Shut Down DTCs P2146 or P2149, Reduced Engine Power (Repair Fuel Injector Control Module (FICM) Harness Chafed Wires) Models: 2001-2004 Chevrolet Kodiak C4500/C5500 Series, Silverado Models 2001-2004 GMC Sierra Models, TopKick C4500/C5500 Series Equipped with Duramax(TM) Diesel Engine RPO LB7 2004-2005 Chevrolet Kodiak, Silverado Models 2004-2005 GMC Sierra Models, TopKick Equipped with Duramax Diesel Engine RPO LLY Please Refer to GMVIS Condition Some customers may comment that the malfunction indicator lamp (MIL) is illuminated or intermittent and there is a significant reduction in engine power (limp home mode). The scan tool may display one or more Injector Driver Circuit DTCs P0201, P0202, P0203, P0204, P0205, P0206, P0207 or P0208 and/or Cylinder Bank Shut Down DTCs P2146 or P2149 set as Current or in History. Cause This condition may be caused by the fuel injector control module (FICM) wiring harness protective conduit rubbing against the back of the alternator, the alternator bracket or the FICM harness retaining bracket. This may result in the conduit rubbing through, exposing the wires inside and chafing of the wire insulation then occurs. Correction 1. Turn ON the ignition, with the engine OFF. 2. Observe the DTC information with the scan tool. 3. If any of the above DTCs are set, then proceed to inspect the FICM wiring harness at the locations outlined in the following steps. 4. Turn OFF the ignition and all accessories and allow the control modules to power down. Note For Silverado and Sierra models only perform Step 5. 5. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. Important DO NOT break off the tab on the electrical connectors. 6. Disconnect the FICM electrical connectors (2) from the FICM (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Control Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel Injector Control Module: > 09-06-04-034 > Aug > 09 > Fuel System - Reduced Engine Power, MIL (Various Codes) > Page 5503 7. Carefully bend up and backwards the FICM wiring harness electrical connectors (1) away from the FICM (4). Note Some of these chafes are very small, possibly the size of a pen tip, but could still cause injector circuit concerns. 8. Inspect the wiring harness for chafing (3) that may result from rubbing at the back of the alternator (2), the alternator bracket or at the FICM harness retaining bracket. If necessary, peel the tape from the area and look for ANY chafes into the wires. ^ If chafing is observed and the conductive portion of the wire IS NOT damaged, apply electrical tape around the wire. ^ If chafing is observed and the conductive portion of the wire IS damaged, then refer to Splicing Copper Wire Using Splice Sleeves in Wiring Repairs in SI. ^ If chafing IS NOT OBSERVED, then refer to the appropriate DTC Diagnostic procedures in SI. 9. Connect the electrical connectors to the FICM. 10. Insulate the harness with suitable material such as conduit or heater hose to prevent a reoccurrence. Note For Silverado and Sierra models only perform Step 11. 11. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 12. Clear the DTCs with a scan tool. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector Control Module: > 09-06-04-034 > Aug > 09 > Fuel System - Reduced Engine Power, MIL (Various Codes) Fuel Injector Control Module: All Technical Service Bulletins Fuel System - Reduced Engine Power, MIL (Various Codes) TECHNICAL Bulletin No.: 09-06-04-034 Date: August 17, 2009 Subject: Malfunction Indicator Lamp (MIL) Illuminated, Fuel Injector Driver Circuit DTCs P0201, P0202, P0203, P0204, P0205, P0206, P0207, P0208 and Cylinder Bank Shut Down DTCs P2146 or P2149, Reduced Engine Power (Repair Fuel Injector Control Module (FICM) Harness Chafed Wires) Models: 2001-2004 Chevrolet Kodiak C4500/C5500 Series, Silverado Models 2001-2004 GMC Sierra Models, TopKick C4500/C5500 Series Equipped with Duramax(TM) Diesel Engine RPO LB7 2004-2005 Chevrolet Kodiak, Silverado Models 2004-2005 GMC Sierra Models, TopKick Equipped with Duramax Diesel Engine RPO LLY Please Refer to GMVIS Condition Some customers may comment that the malfunction indicator lamp (MIL) is illuminated or intermittent and there is a significant reduction in engine power (limp home mode). The scan tool may display one or more Injector Driver Circuit DTCs P0201, P0202, P0203, P0204, P0205, P0206, P0207 or P0208 and/or Cylinder Bank Shut Down DTCs P2146 or P2149 set as Current or in History. Cause This condition may be caused by the fuel injector control module (FICM) wiring harness protective conduit rubbing against the back of the alternator, the alternator bracket or the FICM harness retaining bracket. This may result in the conduit rubbing through, exposing the wires inside and chafing of the wire insulation then occurs. Correction 1. Turn ON the ignition, with the engine OFF. 2. Observe the DTC information with the scan tool. 3. If any of the above DTCs are set, then proceed to inspect the FICM wiring harness at the locations outlined in the following steps. 4. Turn OFF the ignition and all accessories and allow the control modules to power down. Note For Silverado and Sierra models only perform Step 5. 5. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. Important DO NOT break off the tab on the electrical connectors. 6. Disconnect the FICM electrical connectors (2) from the FICM (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector Control Module: > 09-06-04-034 > Aug > 09 > Fuel System - Reduced Engine Power, MIL (Various Codes) > Page 5509 7. Carefully bend up and backwards the FICM wiring harness electrical connectors (1) away from the FICM (4). Note Some of these chafes are very small, possibly the size of a pen tip, but could still cause injector circuit concerns. 8. Inspect the wiring harness for chafing (3) that may result from rubbing at the back of the alternator (2), the alternator bracket or at the FICM harness retaining bracket. If necessary, peel the tape from the area and look for ANY chafes into the wires. ^ If chafing is observed and the conductive portion of the wire IS NOT damaged, apply electrical tape around the wire. ^ If chafing is observed and the conductive portion of the wire IS damaged, then refer to Splicing Copper Wire Using Splice Sleeves in Wiring Repairs in SI. ^ If chafing IS NOT OBSERVED, then refer to the appropriate DTC Diagnostic procedures in SI. 9. Connect the electrical connectors to the FICM. 10. Insulate the harness with suitable material such as conduit or heater hose to prevent a reoccurrence. Note For Silverado and Sierra models only perform Step 11. 11. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 12. Clear the DTCs with a scan tool. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Control Module > Component Information > Technical Service Bulletins > Page 5510 Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Control Module > Component Information > Diagrams > Fuel Injection Control Module - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Control Module > Component Information > Diagrams > Fuel Injection Control Module - C1 > Page 5513 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Control Module > Component Information > Diagrams > Page 5514 Fuel Injector Control Module: Service and Repair FUEL INJECTION CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the fuel fill cap in order to relieve the fuel pressure. 3. Cut the tie strap attaching the harness to the bracket. 4. Disconnect the fuel injection control module (FICM) electrical connectors. Pull the retainers out until the connectors disengage. 5. Remove and discard the fuel line eyebolts. 6. Remove and discard the fuel line eyebolt washers from the banjo fittings. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Control Module > Component Information > Diagrams > Page 5515 7. Remove the FICM bolts. 8. Remove the FICM with insulators. 9. If necessary, remove the oil level indicator tube bracket bolt from the FICM bracket. 10. If necessary, remove the fuel line and engine harness clips from the FICM bracket. 11. If necessary, remove the FICM bracket bolts. 12. If necessary, remove the FICM bracket. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Control Module > Component Information > Diagrams > Page 5516 1. If necessary, install the FICM bracket. 2. If necessary, install the FICM bracket bolts. 3. If necessary, install the fuel line and engine harness clips to the FICM bracket. NOTE: Refer to Fastener Notice in Service Precautions. 4. If necessary, install the oil level indicator tube bracket bolt to the FICM bracket. Tighten Tighten the bolt to 21 N.m (15 lb ft). IMPORTANT: Ensure that the insulators do not get knocked off when installing the FICM to the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Control Module > Component Information > Diagrams > Page 5517 5. Install the FICM with insulators. 6. Install the FICM bolts. Tighten Tighten the bolt to 20 N.m (14 lb ft). 7. Lubricate the NEW eyebolt washers with diesel fuel prior to installing. 8. Install the NEW eyebolt washers to the banjo fittings. 9. Install the NEW fuel line eyebolts. Tighten Tighten the bolt to 34 N.m (25 lb ft). 10. Connect the FICM electrical connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector Control Module > Component Information > Diagrams > Page 5518 Slide the retainers in to engage the connectors. 11. Install a NEW tie strap attaching the harness to the bracket. 12. Connect the negative battery cable. 13. Install the fuel fill cap. 14. Prime the fuel system. Refer to Fuel System Priming. 15. Start the engine. If the engine stalls, repeat the above step. 16. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation Fuel Line Coupler: Description and Operation QUICK-CONNECT FITTINGS Quick-connect fittings provide a simplified means of installing and connecting fuel system components. The fittings consist of a unique female connector and a compatible male pipe end. O-rings, located inside the female connector, provide the fuel seal. Integral locking tabs inside the female connector hold the fittings together. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) Fuel Line Coupler: Service and Repair Quick Connect Fitting(S) Service (Metal Collar) QUICK CONNECT FITTING(S) SERVICE (METAL COLLAR) TOOLS REQUIRED - J 44581 Fuel Line Disconnect Tool - J 43178 Fuel Line Disconnect Tool REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the fuel fill cap. 3. Remove the retainers from the fuel feed and return pipe quick connect fittings. CAUTION: Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 4. Using compressed air, blow any dirt or debris from around the fitting. 5. Using the correct end of J 44581 for the size of the fitting. Insert J 44581 into the female connector, then push inward in order to release the locking tabs. 6. If the vehicle is a cab/chassis, it may be necessary to use J 43178 in order to release the quick connect fittings at the sending unit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 5524 7. Pull the connection apart. 8. Use a clean shop towel in order to wipe off the male end. NOTE: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required. 9. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 1. Apply a few drops of clean engine oil to the male connection end. 2. Push both sides of the fittings together in order to snap the retaining tabs into place. 3. Once installed, pull on both sides of the connections in order to make sure the connection is secure. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 5525 4. Install the retainers to the fuel feed/return pipes. 5. Install the fuel fill cap. 6. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 5526 Fuel Line Coupler: Service and Repair Quick Connect Fitting(S) Service (Plastic Collar) QUICK CONNECT FITTING(S) SERVICE (PLASTIC COLLAR) REMOVAL PROCEDURE IMPORTANT: There are several types of plastic fuel and evaporative emission (EVAP) quick connect fittings used on this vehicle. The following instructions apply to all types of plastic quick connect fittings except where indicated. 1. Disconnect the negative battery cable. 2. Remove fuel fill cap. CAUTION: Refer to Safety Glasses and Compressed Air Caution in Service Precautions. 3. Using compressed air, blow any dirt from around the quick connect fitting. 4. Squeeze the plastic quick connect fitting release tabs together to disengage the quick connect fitting. (This step applies to Bartholomew style fittings ONLY). 5. Squeeze where indicated by the arrows on both sides of the plastic ring to disengage the quick connect fitting. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 5527 6. Squeeze where indicated by the arrows on both sides of the plastic ring to disengage the quick connect fitting. 7. Pull the connection apart. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 1. Apply a few drops of clean engine oil to the male connection end. 2. Push both sides of the quick connect fitting together in order to cause the retaining tabs to snap into place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 5528 3. Once installed, pull on both sides of the quick connect fitting in order to make sure the connection is secure. 4. Install the fuel fill cap. 5. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Engine Controls - Revised DTC 0090 Diagnostics Fuel Pressure Regulator: Technical Service Bulletins Engine Controls - Revised DTC 0090 Diagnostics Bulletin No.: 05-06-04-039 Date: June 07, 2005 SERVICE MANUAL UPDATE Subject: Revised DTC P0090 Models: 2004-2005 Chevrolet Kodiak, Silverado 2004-2005 GMC Sierra, TopKick with 6.6L Diesel Engine (VIN 2 - RPO LLY) This bulletin is being issued to revise DTC P0090 in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. DTC P0090 Circuit Description The engine control module (ECM) supplies power and ground to the fuel rail pressure (FRP) regulator. The ECM monitors current on the circuits to detect a failure. If the current is outside of the expected range, DTC P0090 will set. DTC Descriptor This diagnostic supports the following DTC: DTC P0090 Fuel Pressure Regulator Control Circuit Conditions for Running the DTC ^ The ignition is ON. ^ The commanded FRP regulator current is between 400-1,500 mA. Conditions for Setting the DTC The FRP regulator circuit current is not between 50-1,600 mA. Action Take When the DTC Sets ^ The control module illuminates the malfunction indicator lamp (MIL) when the diagnostic runs and fails. ^ The control module records the operating conditions at the time the diagnostic fails. The control module stores this information in the Freeze Frame/Failure Records. Conditions for Clearing the MIL/DTC ^ The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail. ^ A current DTC, Last Test Failed, clears when the diagnostic runs and passes. ^ A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic. ^ clear the MIL and the DTC with a scan tool. Diagnostic Aids There are no driveability concerns associated with the FRP regulator unless a DTC is present. The most likely cause of this DTC is a sticking FRP regulator. If the fuel system pressure is actually too high, a fuel knock and smoke condition will exist. Test Description Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Engine Controls - Revised DTC 0090 Diagnostics > Page 5533 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Engine Controls - Revised DTC 0090 Diagnostics > Page 5534 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Engine Controls - Revised DTC 0090 Diagnostics > Page 5535 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Engine Controls - Revised DTC 0090 Diagnostics > Page 5536 The numbers below refer to the step numbers on the diagnostic table. 7. This step tests for battery voltage through the ECM to the FRP regulator. 8. This step tests for an open control circuit between the ECM and the FRP regulator. 9. This excessive current code can be set by voltage being applied between the ECM and the FRP regulator on the FRP control circuit. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Page 5537 Fuel Pressure Regulator Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Page 5538 Fuel Pressure Regulator: Testing and Inspection FUEL PRESSURE REGULATOR DIAGNOSIS The Fuel Pressure Regulator graphing procedure offers valuable information on regulator performance by comparing desired and actual fuel rail pressure. An almost perfect comparison between actual rail pressure and desired rail pressure is found on a fairly new, low mileage engine. A minor ripple is acceptable behavior for the fuel rail pressure regulator and is seen on high mileage engines. A 'shark tooth' fluctuation in actual fuel rail pressure indicates a sticking pressure regulator. 1. Set up the following Min/Max ranges for graphing the fuel rail pressure on the scan tool. - Engine Speed Min/Max range is 0-1,000 RPM. - Actual Fuel Rail Pressure Min/Max range is 1-160 MPa. - Desired Fuel Rail Pressure Min/Max is 1-160 MPa. 2. Start and idle the engine. 3. Observe the live plot for sharp changes or shark tooth pattern in the Actual Fuel Rail Pressure while performing the following actions: - Idling the engine - Shifting the transmission from Park to Drive and back to Park - Turning the steering from left stop position to right stop position - Turning the air conditioning ON and OFF Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Page 5539 4. If there is a violent fluctuation in the Actual Fuel Rail Pressure, as seen in the surging graph, replace the fuel pressure regulator. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Page 5540 Fuel Pressure Regulator: Service and Repair FUEL PRESSURE REGULATOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the air intake pipe. 2. Disconnect the air conditioning (A/C) compressor clutch electrical connector. 3. Disconnect the A/C cut out switch electrical connector. 4. Remove the A/C compressor bolts. 5. Remove the generator. 6. Reposition the A/C compressor (with the hoses attached) to the right side of the engine compartment. 7. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors. 8. Open the harness clip (2). 9. Remove the main engine electrical harness connectors. 10. Disconnect the barometric pressure (BARO) sensor electrical connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Page 5541 11. Remove the main engine harness electrical connector bolts. 12. Remove the main connectors from the bracket. 13. Disconnect the engine coolant temperature (ECT) sensor electrical connector. 14. Remove the water outlet tube. 15. Disconnect the fuel temperature sensor electrical connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Page 5542 16. Disconnect the fuel pressure regulator electrical connector (1). 17. Disconnect the oil level sensor harness electrical connector. 18. Reposition the distribution block hose clamps. 19. Remove the distribution block hoses from the distribution block. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Page 5543 20. Clean the fuel pressure regulator and high pressure injection pump thoroughly with solvent, such as GM P/N 12377981 (Canadian P/N 10953463) or equivalent. 21. Using compressed air, thoroughly blow dry the regulator and pump. 22. Remove the 3 fuel pressure regulator screws (1) using a T25 TORX(R). 23. Remove the fuel pressure regulator (1). 24. If dirt or debris is found in the bore or seating surfaces of the fuel injection pump, perform the following: - Place a clean rag over the bore on order to collect the excess fuel. - Bump the engine over in order to flush any debris out of the regulator bore. INSTALLATION PROCEDURE IMPORTANT: If the pressure regulator is being re-used, check the O-rings for damage. If the O-rings are damaged, install NEW O-rings. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Page 5544 1. Lubricate and install NEW O-rings onto the regulator. Lubricate the O-rings with clean, NEW engine oil. IMPORTANT: If the regulator is installed at an angle the O-rings may be damaged, resulting in possible fuel leakage. 2. Install the fuel pressure regulator (1). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the 3 fuel pressure regulator screws (1) using a T25 TORX(R). Tighten Tighten the screws a first pass to 4 N.m (35 lb in). - Tighten the screws a final pass to 7 N.m (62 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Page 5545 1. Install the distribution block hoses to the distribution block. 2. Position the distribution block hose clamps. 3. Connect the oil level sensor harness electrical connector. 4. Connect the fuel pressure regulator electrical connector (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Page 5546 5. Connect the fuel temperature sensor electrical connector. 6. Install the water outlet tube. 7. Connect the ECT sensor electrical connector. 8. Install the main connectors to the bracket. 9. Install the main engine harness electrical connector bolts. Tighten Tighten the bolts to 21 N.m (15 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Page 5547 10. Connect the BARO sensor electrical connector. 11. Connect the main engine electrical harness connectors. 12. Push down on the latches (1) in order to connect the connectors. 13. Close the harness clip (2). 14. Position the A/C compressor. 15. Install the A/C compressor bolts. Tighten Tighten the bolts to 50 N.m (37 lb ft). 16. Connect the A/C cut out switch electrical connector. 17. Connect the A/C compressor clutch electrical connector. 18. Install the generator. 19. Install the air intake pipe. 20. Prime the fuel system. Refer to Fuel System Priming. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Page 5548 21. Start the engine. If the engine stalls, repeat the above step. 22. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations FUEL SCHRADER VALVE The Fuel Schrader Valve is located on the right front of the engine, on the right upper valve rocker Arm cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations FUEL SCHRADER VALVE The Fuel Schrader Valve is located on the right front of the engine, on the right upper valve rocker Arm cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations FUEL PUMP RELAY - SECONDARY (Vehicles with Dual Tanks Only) Fuel Pump Relay-Secondary-With Dual Tanks The Fuel Pump Relay - Secondary is attached to the Underhood Fuse Block Bracket. The Underhood Fuse Block is located at the left side of the engine compartment, to the rear of the battery. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Service Information Fuel Rail: Technical Service Bulletins Fuel System - Fuel Injector Service Information INFORMATION Bulletin No.: 03-06-04-036B Date: November 10, 2009 Subject: Information on Servicing Duramax(TM) Fuel Injectors to Avoid and Remove Contamination Models: 2001-2010 Chevrolet Silverado 2003-2009 Chevrolet Kodiak C4500/C5500 Series 2006-2010 Chevrolet Express Vans 2001-2010 GMC Sierra 2003-2009 GMC TopKick C4500/C5500 Series 2006-2010 GMC Savana Vans Equipped with 6.6L Duramax(TM) Diesel Engine RPOs LB7, LLY, LMM, LBZ Please Refer to GMVIS Supercede: This bulletin is being revised to add model years and update the Parts Information. Please discard Corporate Bulletin Number 03-06-04-036A (Section 06 - Engine/Propulsion System). Fuel injectors may become contaminated during engine servicing. Debris between the injector line and the injector line nut may fall into the injector fuel inlet upon removal. Refer to the following SI procedures for the appropriate model year, vehicle and engine RPO when performing the following bulletin procedures for servicing the fuel injectors and lines. - Fuel Injection Fuel Rail Assembly Replacement - Bank 1 - Fuel Injection Fuel Rail Assembly Replacement - Bank 2 - Fuel Injector Replacement (Right) - Fuel Injector Replacement (Left) Removal of Fuel Injector Lines 1. Before removing the fuel injector line, use regulated compressed air to blow any debris from between the fuel injector line and the fittings (1, 2). Wipe the fittings (1, 2) clean of debris. 2. Spray Super Lube(R), P/N 12346241 (in Canada, P/N 10953474), or a lithium grease equivalent, between the fuel injector line and fittings (1, 2) to assist in containing any debris during removal. 3. Remove the fuel injector line. 4. Remove the upper valve cover. 5. Remove the lower valve cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Service Information > Page 5564 Notice After the fuel line is removed and the fuel injector inlet is exposed, DO NOT use compressed air to clean debris. Using compressed air can allow debris to enter the fuel injector inlet and damage the fuel injector. 6. Immediately after removal of the lower valve cover, use a vacuum source to remove any contamination in the fuel injector inlet (1). Fuel Injector Cleaning and Inspection Notice The fuel injector must be cleaned with the proper cleaning equipment. DO NOT use abrasive cleaning methods such as a metallic brush to remove deposits. Cleaning an injector with improper tools may damage the fuel injector. 1. Use a soft bristle non-metallic brush and fuel injector cleaner, P/N 88861802 (in Canada, P/N 88861804), or equivalent, to remove any deposits from the nozzle tip (1) and the copper washer sealing area (2) before reinstallation. 2. Inspect the fuel injector nozzle tip (1) for cracks, dents, or other damage. 3. Inspect the nozzle tip (1) for any signs of discoloration (dark yellow, tan, or blue) due to excessive heat. Note For information on injector bore cleaning, refer to Corporate Bulletin Number 05-06-04-067 Information on New Essential Tool EN-47909 Injector Bore Cleaning Kit for 6.6L Duramax(TM) Diesel Engine. ‹› If any damage is found replace the fuel injector. Clean the fuel injector bore BEFORE installing the new fuel injector. 4. Clean the fuel injector high-pressure lines by performing the following steps: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Service Information > Page 5565 5. Inspect the fuel injector high-pressure line for excessive corrosion, scale or rust to the sealing surface as shown. Notice Medium size media glass beads have a cleaning and peening action and do not remove metal. They do not have the quick abrasive action of sharp edged media. Glass beads clean rust, scale and corrosion from metal parts without any damage. 6. Use an Abrasive Blasting Cabinet, P/N 624-AST-SBC1, (to order, call GM Dealer Equipment), or equivalent, with a medium size media glass beads to clean the high pressure lines and fittings. Important Black plastic electrical tape or equivalent will protect the fittings outside coating from being removed with the media. This must be done to ALL sixteen high pressure fittings. 7. Install black plastic electrical tape or equivalent on both of the fittings (1) as shown. 8. When using an Abrasive Blasting Cabinet or equivalent, make sure you only clean the inside of the fittings (2) and as much of the fitting threads as possible as shown. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Service Information > Page 5566 9. Use pipe cleaners (1) to block the ends of the high pressure lines so the abrasive blasting glass beads will not contaminate the inside of the pipes. Before removing the pipe cleaners, clean them by using regulated compressed air to blow any debris and/or media glass beads from the pipe cleaners. 10. There may be some area of the fitting or line that the glass beads did not clean very well. Disregard any surface that did not clean up as long as the area of the fitting is clean at the bite edge or sealing surface. Refer to the above illustration (1). Replace any suspect high pressure line if the glass beads cannot remove corrosion, scale or rust from the sealing surfaces and/or pitting or any other damage that is found. 11. After cleaning all of the fuel injector high-pressure line fittings with the glass beads, clean by using compressed air to blow any debris and/or media glass beads from inside and outside of all the fittings and lines. Afterwards, wash thoroughly with All Purpose Parts Cleaner, P/N 88862650 (in Canada, P/N 88901247, Brake Parts Cleaner) or equivalent. Repeat this process until all of the debris and/or media glass beads have been removed from the fittings and lines. Fuel Injector Installation Install the fuel injectors and lines using published service procedures in SI. Notice Ensure proper torquing of the fuel injector line fittings (1, 2). An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting may cause a fuel leak. Inspection For Fuel Leaks Into the Engine After Repair 1. Run the engine at idle for 10 minutes. Inspect for external fuel leaks while the engine is running. 2. Stop the engine and wait 10 minutes, then check the engine oil level. This will be the initial oil level. 3. Run the engine at idle for 5 minutes while commanding the fuel pressure to 160 MPa using a scan tool. 4. Stop the engine and wait 10 minutes, then check the oil level. ‹› If the engine oil level is more than 4.7 mm (3/16 in) above the initial oil level, refer to Fuel Leak Diagnosis (Inside of Engine), and Fuel in Engine Oil procedures in the Engine Controls and Engine Mechanical sections respectively in SI. ‹› If the engine oil level is less than 4.7 mm (3/16 in) above the initial oil level, the repair is complete. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Service Information > Page 5567 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 5568 Fuel Rail: Description and Operation FUEL RAIL ASSEMBLIES The left and right fuel rail assemblies attach to the cylinder heads. The fuel rail assemblies distribute pressurized fuel to the fuel injectors through the fuel lines. The fuel rail assemblies consists of the following components: - The fuel rail pressure sensor in the right fuel rail - The fuel pressure relief valve in the left fuel rail The fuel rail pressure sensor gives the engine control module (ECM) an indication of fuel pressure. The ECM uses this information to regulate fuel pressure, by commanding the fuel pressure regulator open or closed on the inlet of the fuel injection pump. The fuel pressure relief valve opens only to prevent excessive pressure in the event of a malfunction. Fuel from the fuel pressure relief valve is returned to the fuel tank. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement - Bank 1 Fuel Rail: Service and Repair Fuel Rail Assembly Replacement - Bank 1 FUEL RAIL ASSEMBLY REPLACEMENT - BANK 1 REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the water outlet tube. 3. Remove the battery cable junction block bracket bolt (1) from the power steering pump bracket. 4. Reposition the junction block and bracket. IMPORTANT: After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects. 5. Loosen the charged air cooler inlet duct to turbocharger clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting. 6. Remove the charged air cooler inlet duct connector (4) from the turbocharger. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement - Bank 1 > Page 5571 7. Disconnect the fuel feed and return line quick connect fittings. 8. Remove the fuel line bracket nut. 9. Remove the fuel line bracket from the stud. 10. Remove the positive crankcase ventilation (PCV) hose/pipe. 11. Remove the air conditioning (A/C) compressor bolts. 12. Reposition the A/C compressor aside. 13. Remove the banjo bolt and washer from the fuel injection control module. 14. Remove the fuel feed pipe nuts/bolts. 15. Remove the fuel feed pipe. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement - Bank 1 > Page 5572 16. Disconnect the fuel rail balance pipe from the fuel rails. 17. Remove the fuel rail balance pipe bolts. 18. Remove the fuel rail balance pipe. 19. Disconnect the fuel injector return hose from the return/junction block line. 20. Reposition the return/junction block hose clamps at the injection pump. 21. Remove the fuel hoses from the return/junction block. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement - Bank 1 > Page 5573 22. Reposition the return/junction block hose clamp at the rear of the left fuel rail. 23. Remove the fuel hose from the fuel rail. 24. Remove the return/junction block fuel line clip bolts. 25. Remove the return/junction block and lines. 26. Remove the fuel pipe bracket bolts. 27. Remove the fuel pipe bracket. 28. Disconnect the fuel inlet pipe from the fuel rail. 29. Disconnect the fuel inlet pipe from the injection pump. 30. Remove the inlet fuel pipe. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement - Bank 1 > Page 5574 31. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris. 32. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal. NOTE: DO NOT use compressed air to clean debris from the fuel injector inlet after the fuel line is removed. Using compressed air can allow debris to enter the fuel injector inlet and damage the fuel injector. 33. Remove the left fuel injector pipes. 34. Remove the fuel rail bolts. 35. Remove the fuel rail and bracket. INSTALLATION PROCEDURE Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement - Bank 1 > Page 5575 1. Install the fuel rail and bracket. 2. Install the fuel rail bolts. Tighten Tighten the bolts to 25 N.m (18 lb ft). NOTE: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak. 3. Install the fuel injector pipes. Tighten Tighten the fittings to 41 N.m (30 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement - Bank 1 > Page 5576 4. Remove the inlet fuel pipe. 5. Connect the fuel inlet pipe to the injection pump. 6. Connect the fuel inlet pipe to the fuel rail. Tighten Tighten the fittings to 41 N.m (30 lb ft). 7. Install the fuel pipe bracket. 8. Install the fuel pipe bracket bolts. Tighten Tighten the bolts to 25 N.m (18 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement - Bank 1 > Page 5577 9. Install the return/junction block and lines. 10. Install the return/junction block fuel line clip bolts. Tighten Tighten the bolts 25 N.m (18 lb ft). 11. Install the fuel hose to the fuel rail. 12. Position the return/junction block hose clamp at the rear of the left fuel rail. 13. Install the fuel hoses to the return/junction block. 14. Position the return/junction block hose clamps at the injection pump. 15. Connect the fuel injector return hose to the return/junction block line. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement - Bank 1 > Page 5578 16. Install the fuel rail balance pipe. 17. Connect the fuel rail balance pipe to the fuel rails. Tighten Tighten the fittings to 41 N.m (30 lb ft). 18. Install the fuel rail balance pipe bolts. Tighten Tighten the bolts 25 N.m (18 lb ft). 19. Install the fuel feed pipe. 20. Install the fuel feed pipe nut/bolt. Tighten Tighten the nut/bolt to 25 N.m (18 lb ft). 21. Install the banjo bolt and washer to the fuel injection control module. Tighten Tighten the bolt to 40 N.m (29 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement - Bank 1 > Page 5579 22. Position the A/C compressor aside. 23. Install the A/C compressor bolts. Tighten Tighten the bolts to 50 N.m (37 lb ft). 24. Install the PCV hose/pipe. 25. Install the fuel line bracket to the stud. 26. Install the fuel line bracket nut. Tighten Tighten the nut to 21 N.m (15 lb ft). 27. Connect the fuel feed and return line quick connect fittings. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement - Bank 1 > Page 5580 28. Remove the tape from the turbocharger openings. IMPORTANT: Lubricate the end of the duct prior to installation. 29. Install the charged air cooler inlet duct connector (4) to the turbocharger. 30. Tighten the charged air cooler inlet duct to turbocharger clamp (1). Tighten Tighten the clamp to 6 N.m (53 lb in). 31. Position the junction block and bracket. 32. Install the battery cable junction block bracket bolt (1) to the power steering pump bracket. Tighten Tighten the bolt to 9 N.m (80 lb in). 33. Install the water outlet tube. 34. Connect the negative battery cable. 35. Prime the fuel system. Refer to Fuel System Priming. 36. Start the engine. If the engine stalls, repeat the above step. 37. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement - Bank 1 > Page 5581 Fuel Rail: Service and Repair Fuel Rail Assembly Replacement - Bank 2 FUEL RAIL ASSEMBLY REPLACEMENT - BANK 2 REMOVAL PROCEDURE 1. Disconnect the negative battery cables. 2. Remove the air cleaner outlet duct. 3. Remove the fuel injection control module (FICM). 4. Remove the fuel filter. 5. Remove the exhaust gas recirculation (EGR) cooler tube. 6. Remove the positive crankcase ventilation (PCV) hose/pipe. 7. Disconnect the fuel rail balance pipe from the fuel rails. 8. Remove the fuel rail balance pipe bolts. 9. Remove the fuel rail balance pipe. 10. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris. 11. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal. NOTE: DO NOT use compressed air to clean debris from the fuel injector inlet after the fuel line is removed. Using compressed air can allow debris to enter the fuel injector inlet and damage the fuel injector. 12. Remove the fuel injector pipes. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement - Bank 1 > Page 5582 13. Remove the fuel rail bolts. 14. Remove the fuel rail. INSTALLATION PROCEDURE Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 1. Install the fuel rail. 2. Install the fuel rail bolts. Tighten Tighten the bolts to 25 N.m (18 lb ft). NOTE: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Assembly Replacement - Bank 1 > Page 5583 3. Install the fuel injector pipes. Tighten Tighten the fittings to 41 N.m (30 lb ft). 4. Install the fuel rail balance pipe. 5. Connect the fuel rail balance pipe to the fuel rails. Tighten Tighten the fittings to 41 N.m (30 lb ft). 6. Install the fuel rail balance pipe bolts. Tighten Tighten the bolts 25 N.m (18 lb ft). 7. Install the PCV hose/pipe. 8. Install the EGR cooler tube. 9. Install the fuel filter. 10. Install the FICM. 11. Install the air cleaner outlet duct. 12. Connect the negative battery cables. 13. Prime the fuel system. Refer to Fuel System Priming. 14. Start the engine. If the engine stalls, repeat the above step. 15. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation Fuel Return Line: Description and Operation FUEL FEED AND RETURN PIPES The fuel feed pipe carries fuel from the fuel tank to the fuel injector control module. The fuel return pipe carries fuel from the fuel rail assemblies back to the fuel tank. The fuel pipes consist of 2 sections: The rear fuel pipe assemblies are located from the top of the fuel tank to the chassis fuel pipes. The rear fuel pipes are constructed of steel with sections of rubber hose covered with braiding. - The chassis fuel pipes are located under the vehicle and connect the rear fuel pipes to the fuel rail pipes. These pipes are constructed of steel with sections of rubber hose covered with braiding. FUEL INJECTORS AND RETURN LINES A fuel injector is a solenoid device, controlled by the fuel injection control module (FICM), that meters pressurized fuel to a single engine cylinder. The engine control module (ECM) energizes the low-impedance injector solenoid to open a normally closed valve. Fuel pressure is released from above the fuel injector pintle, and is returned to the fuel tank through the fuel return lines. The difference in fuel pressure above and below the pintle causes the pintle to open. Fuel from the fuel injector tip is sprayed directly into the combustion chamber on the compression stroke of the engine. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Feed and Fuel Return Pipe Purge Procedure Fuel Return Line: Service and Repair Fuel Feed and Fuel Return Pipe Purge Procedure FUEL FEED AND FUEL RETURN PIPE PURGE PROCEDURE 1. Pump the primer located on top of the fuel filter 30 times or until stiff. 2. Attempt to start and run the engine. If the engine does not start, repeat step 1. 3. Allow to run for 5 minutes at idle. 4. Check for fuel leaks. 5. Clear all engine diagnostic trouble codes (DTCs). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Feed and Fuel Return Pipe Purge Procedure > Page 5589 Fuel Return Line: Service and Repair Fuel Return Pipe Replacement FUEL RETURN PIPE REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine wiring harness. 2. Remove the water outlet. 3. Remove the exhaust gas recirculation (EGR) cooler tube. 4. Reposition the fuel return line hose clamps (1). 5. Remove the fuel return line hoses from the return line. 6. Remove the fuel return line clamp bolts (1). 7. Reposition the fuel return line hose clamp (3) from the fuel rail. 8. Remove the fuel return line hose from the fuel rail. 9. Remove the fuel return line (2). REMOVAL PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Feed and Fuel Return Pipe Purge Procedure > Page 5590 1. Install the fuel return line (2). 2. Install the fuel return line hose to the fuel rail. 3. Position the fuel return line hose clamp (3) at the fuel rail. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the fuel return line clamp bolts (1). Tighten Tighten the bolts to 25 N.m (18 lb ft). 5. Install the fuel return line hoses to the return line. 6. Position the fuel return line hose clamps (1). 7. Install the EGR cooler tube. 8. Install the water outlet. 9. Install the engine wiring harness. 10. Prime the fuel system. Refer to Fuel System Priming. 11. Start the engine. If the engine stalls, repeat the above step. 12. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Feed and Fuel Return Pipe Purge Procedure > Page 5591 Fuel Return Line: Service and Repair Fuel Return Hose Replace - Fuel Return to Fuel Injection Pump FUEL RETURN HOSE REPLACEMENT - FUEL RETURN PIPE TO FUEL INJECTION PUMP REMOVAL PROCEDURE 1. Remove the water outlet. 2. Remove the air intake tube. 3. Reposition the fuel hose clamps (1) at the return/feed line as required. 4. Disconnect the fuel hoses from the return/feed line as required. 5. Reposition the fuel hose clamps (1) at the injection pump as required. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Feed and Fuel Return Pipe Purge Procedure > Page 5592 6. Disconnect the fuel hoses (2, 3) from the injection pump as required. 7. Remove the fuel hoses from the vehicle as required. REMOVAL PROCEDURE 1. Install the fuel hoses to the vehicle as required. 2. Connect the fuel hoses (2, 3) to the injection pump as required. 3. Position the fuel hose clamps (1) at the injection pump as required. 4. Connect the fuel hoses to the return/feed line as required. 5. Position the fuel hose clamps (1) at the return/feed line as required. 6. Install the air intake tube. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Feed and Fuel Return Pipe Purge Procedure > Page 5593 7. Install the water outlet 8. Prime the fuel system. Refer to Fuel System Priming. 9. Start the engine. If the engine stalls, repeat the above step. 10. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Feed and Fuel Return Pipe Purge Procedure > Page 5594 Fuel Return Line: Service and Repair Fuel Injector Return Pipe Replacement -Left FUEL INJECTOR RETURN PIPE REPLACEMENT -LEFT REMOVAL PROCEDURE 1. Remove the glow plug controller. 2. Disconnect the return line from the return/junction block line. 3. Remove the fuel return line clips. 4. Remove the fuel injector return line from the injectors. INSTALLATION PROCEDURE 1. Install the fuel injector return line to the injectors. 2. Install the fuel return line clips. 3. Connect the return line to the return/junction block line. 4. Install the glow plug controller. 5. Prime the fuel system. Refer to Fuel System Priming. 6. Start the engine. If the engine stalls, repeat the above step. 7. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Feed and Fuel Return Pipe Purge Procedure > Page 5595 Fuel Return Line: Service and Repair Fuel Feed and Fuel Return Pipe Purge Procedure FUEL FEED AND FUEL RETURN PIPE PURGE PROCEDURE 1. Pump the primer located on top of the fuel filter 30 times or until stiff. 2. Attempt to start and run the engine. If the engine does not start, repeat step 1. 3. Allow to run for 5 minutes at idle. 4. Check for fuel leaks. 5. Clear all engine diagnostic trouble codes (DTCs). Fuel Return Pipe Replacement FUEL RETURN PIPE REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine wiring harness. 2. Remove the water outlet. 3. Remove the exhaust gas recirculation (EGR) cooler tube. 4. Reposition the fuel return line hose clamps (1). 5. Remove the fuel return line hoses from the return line. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Feed and Fuel Return Pipe Purge Procedure > Page 5596 6. Remove the fuel return line clamp bolts (1). 7. Reposition the fuel return line hose clamp (3) from the fuel rail. 8. Remove the fuel return line hose from the fuel rail. 9. Remove the fuel return line (2). REMOVAL PROCEDURE 1. Install the fuel return line (2). 2. Install the fuel return line hose to the fuel rail. 3. Position the fuel return line hose clamp (3) at the fuel rail. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the fuel return line clamp bolts (1). Tighten Tighten the bolts to 25 N.m (18 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Feed and Fuel Return Pipe Purge Procedure > Page 5597 5. Install the fuel return line hoses to the return line. 6. Position the fuel return line hose clamps (1). 7. Install the EGR cooler tube. 8. Install the water outlet. 9. Install the engine wiring harness. 10. Prime the fuel system. Refer to Fuel System Priming. 11. Start the engine. If the engine stalls, repeat the above step. 12. Once the engine starts, inspect for fuel leaks. Fuel Return Hose Replace - Fuel Return to Fuel Injection Pump FUEL RETURN HOSE REPLACEMENT - FUEL RETURN PIPE TO FUEL INJECTION PUMP REMOVAL PROCEDURE 1. Remove the water outlet. 2. Remove the air intake tube. 3. Reposition the fuel hose clamps (1) at the return/feed line as required. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Feed and Fuel Return Pipe Purge Procedure > Page 5598 4. Disconnect the fuel hoses from the return/feed line as required. 5. Reposition the fuel hose clamps (1) at the injection pump as required. 6. Disconnect the fuel hoses (2, 3) from the injection pump as required. 7. Remove the fuel hoses from the vehicle as required. REMOVAL PROCEDURE 1. Install the fuel hoses to the vehicle as required. 2. Connect the fuel hoses (2, 3) to the injection pump as required. 3. Position the fuel hose clamps (1) at the injection pump as required. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Feed and Fuel Return Pipe Purge Procedure > Page 5599 4. Connect the fuel hoses to the return/feed line as required. 5. Position the fuel hose clamps (1) at the return/feed line as required. 6. Install the air intake tube. 7. Install the water outlet 8. Prime the fuel system. Refer to Fuel System Priming. 9. Start the engine. If the engine stalls, repeat the above step. 10. Once the engine starts, inspect for fuel leaks. Fuel Injector Return Pipe Replacement -Left FUEL INJECTOR RETURN PIPE REPLACEMENT -LEFT REMOVAL PROCEDURE 1. Remove the glow plug controller. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Feed and Fuel Return Pipe Purge Procedure > Page 5600 2. Disconnect the return line from the return/junction block line. 3. Remove the fuel return line clips. 4. Remove the fuel injector return line from the injectors. INSTALLATION PROCEDURE 1. Install the fuel injector return line to the injectors. 2. Install the fuel return line clips. 3. Connect the return line to the return/junction block line. 4. Install the glow plug controller. 5. Prime the fuel system. Refer to Fuel System Priming. 6. Start the engine. If the engine stalls, repeat the above step. 7. Once the engine starts, inspect for fuel leaks. Fuel Injector Return Pipe Replacement - Right FUEL INJECTOR RETURN PIPE REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the fuel injection control module (FICM). 2. Remove the fuel filter and bracket. 3. Disconnect the return line from the return/junction block line. 4. Remove the fuel return line clips. 5. Remove the fuel injector return line from the injectors. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Feed and Fuel Return Pipe Purge Procedure > Page 5601 1. Install the fuel injector return line to the injectors. 2. Install the fuel return line clips. 3. Connect the return line to the return/junction block line. 4. Install the fuel filter and bracket. 5. Install the FICM. 6. Prime the fuel system. Refer to Fuel System Priming. 7. Start the engine. If the engine stalls, repeat the above step. 8. Once the engine starts, inspect for fuel leaks. Fuel Return Junction Block Replacement FUEL RETURN JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Reposition the fuel hose clamp at the return/junction block. 2. Remove the hose (1) from the return/junction block. 3. Disconnect the right fuel return line from the return/junction block line. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Feed and Fuel Return Pipe Purge Procedure > Page 5602 4. Reposition the return/junction block hose clamps (3). 5. Remove the return/junction block hoses. 6. Remove the return/junction block line clamp bolt (2). 7. Remove the return/junction block bolt (1). 8. Remove the return/junction block. INSTALLATION PROCEDURE 1. Install the return/junction block. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Feed and Fuel Return Pipe Purge Procedure > Page 5603 2. Install the return/junction block bolt (1). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the return/junction block line clamp bolt (2). Tighten Tighten the bolts to 25 N.m (18 lb ft). 4. Install the return/junction block hoses. 5. Position the return/junction block hose clamps (3). 6. Connect the right fuel return line to the return/junction block line. 7. Install the hose (1) to the return/junction block. 8. Position the fuel hose clamp at the return/junction block. 9. Prime the fuel system. Refer to Fuel System Priming. 10. Start the engine. If the engine stalls, repeat the above step. 11. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation Fuel Supply Line: Description and Operation FUEL FEED AND RETURN PIPES The fuel feed pipe carries fuel from the fuel tank to the fuel injector control module. The fuel return pipe carries fuel from the fuel rail assemblies back to the fuel tank. The fuel pipes consist of 2 sections: The rear fuel pipe assemblies are located from the top of the fuel tank to the chassis fuel pipes. The rear fuel pipes are constructed of steel with sections of rubber hose covered with braiding. - The chassis fuel pipes are located under the vehicle and connect the rear fuel pipes to the fuel rail pipes. These pipes are constructed of steel with sections of rubber hose covered with braiding. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement Fuel Supply Line: Service and Repair Fuel Feed Pipe Replacement FUEL FEED PIPE REPLACEMENT REMOVAL PROCEDURE 1. Remove the water outlet tube. 2. Disconnect the fuel feed line quick connect fitting. 3. Remove the fuel injection control module upper banjo bolt and washer. 4. Reposition the exhaust gas recirculation (EGR) coolant pipe hose clamp. 5. Remove the EGR coolant pipe hose. 6. Remove the EGR coolant pipe bolts. 7. Remove the EGR coolant pipe. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5609 8. Remove the fuel feed pipe nut and clip bolts. 9. Remove the fuel feed pipe. INSTALLATION PROCEDURE 1. Install the fuel feed pipe. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel feed pipe nut and clip bolts. Tighten Tighten the bolts/nut to 41 N.m (30 lb ft). 3. Install the EGR coolant pipe. 4. Install the EGR coolant pipe bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5610 Tighten Tighten the bolts to 25 N.m (18 lb ft). 5. Install the EGR coolant pipe hose. 6. Position the EGR coolant pipe hose clamp. 7. Lubricate a NEW washer with diesel fuel. 8. Install the fuel injection control module upper banjo bolt and the NEW washer. Tighten Tighten the bolt to 34 N.m (25 lb ft). 9. Connect the fuel feed line quick connect fitting. 10. Install the water outlet tube. 11. Prime the fuel system. Refer to Fuel System Priming. 12. Start the engine. If the engine stalls, repeat the above step. 13. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5611 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - (Pickup) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (PICKUP) REMOVAL PROCEDURE 1. Disconnect the fuel feed and return lines. 2. Remove the fuel line bracket nut. 3. Remove the fuel line bracket from the stud. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Remove the fuel bundle clips (2) from the transmission brackets (1). 6. Disconnect the chassis harness from the retaining clips. 7. Remove the fuel system cooler, if necessary. 8. Disconnect the fuel feed and return lines from the fuel tank lines. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5612 9. Remove the fuel bundle nuts from the chassis. 10. Loosen the electronic brake control module (EBCM) bracket bolts (4). 11. Allow the EBCM to remain loose in order to allow fuel pipe clearance. 12. Remove the fuel bundle using the following procedure: 12.1. Guide the fuel bundle pipes towards the rear of the vehicle to clear the engine. 12.2. Lower the fuel bundle while moving it forward and out. INSTALLATION PROCEDURE 1. Install the fuel pipe bundle using the following procedure: 1.1. Install the fuel bundle to the chassis by guiding the pipes towards the rear of vehicle. 1.2. Lift the fuel pipes, while guiding the forward portion of the pipes up towards the engine connections. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel bundle nuts to the chassis. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5613 Tighten Tighten the nuts to 16 N.m (12 lb ft). 3. Connect the fuel feed and return lines to the fuel tank lines. 4. Install the fuel system cooler, if necessary. 5. Connect the fuel bundle clips (2) to the transmission brackets (1). 6. Tighten the EBCM bracket bolts (4). Tighten Tighten the bolts to 25 N.m (18 lb ft). 7. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5614 8. Install the fuel line bracket to the stud. 9. Install the fuel line bracket nut. Tighten Tighten the nut to 16 N.m (12 lb ft). 10. Connect the fuel feed and return lines. 11. Prime the fuel system. Refer to Fuel System Priming. 12. Start the engine. If the engine stalls, repeat the above step. 13. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5615 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - (Cab/Chassis) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (CAB/CHASSIS) REMOVAL PROCEDURE 1. Disconnect the fuel feed and return lines. 2. Remove the fuel line bracket nut. 3. Remove the fuel line bracket from the stud. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Remove the fuel bundle clips (2) from the transmission brackets (1). 6. Disconnect the chassis harness from the retaining clips. 7. Remove the fuel system cooler, if necessary. 8. Disconnect the fuel feed and return lines from the fuel tank lines. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5616 9. Remove the fuel bundle nuts from the chassis. 10. Loosen the electronic brake control module (EBCM) bracket bolts (4). 11. Allow the EBCM to remain loose in order to allow fuel pipe clearance. 12. Remove the fuel bundle using the following procedure: 12.1. Guide the fuel bundle pipes towards the rear of vehicle to clear the engine. 12.2. Lower the fuel bundle while moving it foreword and out. INSTALLATION PROCEDURE 1. Install the fuel pipe bundle using the following procedure: 1.1. Install the fuel bundle to the chassis by guiding the pipes towards the rear of vehicle. 1.2. Lift the fuel pipes, while guiding the forward portion of the pipes up towards the engine connections. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel bundle nuts to the chassis. Tighten Tighten the nuts to 16 N.m (12 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5617 3. Connect the fuel feed and return lines to the fuel tank lines. 4. Install the fuel system cooler, if necessary. 5. Connect the fuel bundle clips (2) to the transmission brackets (1). 6. Tighten the EBCM bracket bolts (4). Tighten Tighten the bolts to 25 N.m (18 lb ft). 7. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5618 8. Install the fuel line bracket to the stud. 9. Install the fuel line bracket nut. Tighten Tighten the nut to 16 N.m (12 lb ft). 10. Connect the fuel feed and return lines. 11. Prime the fuel system. Refer to Fuel System Priming. 12. Start the engine. If the engine stalls, repeat the above step. 13. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5619 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - (Cab/Chassis - W/Balance Pump) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (CAB/CHASSIS W/BALANCE PUMP) REMOVAL PROCEDURE 1. Remove the front and auxiliary fuel tanks. 2. Disconnect the pressure balance pump electrical connector. 3. Remove the fuel bundle nuts. 4. Remove the fuel bundle. INSTALLATION PROCEDURE 1. Install the fuel bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel bundle nuts. Tighten Tighten the nuts to 16 N.m (12 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5620 3. Connect the pressure balance pump electrical connector. 4. Install the front and auxiliary fuel tanks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5621 Fuel Supply Line: Service and Repair Fuel Feed Pipe Replacement FUEL FEED PIPE REPLACEMENT REMOVAL PROCEDURE 1. Remove the water outlet tube. 2. Disconnect the fuel feed line quick connect fitting. 3. Remove the fuel injection control module upper banjo bolt and washer. 4. Reposition the exhaust gas recirculation (EGR) coolant pipe hose clamp. 5. Remove the EGR coolant pipe hose. 6. Remove the EGR coolant pipe bolts. 7. Remove the EGR coolant pipe. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5622 8. Remove the fuel feed pipe nut and clip bolts. 9. Remove the fuel feed pipe. INSTALLATION PROCEDURE 1. Install the fuel feed pipe. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel feed pipe nut and clip bolts. Tighten Tighten the bolts/nut to 41 N.m (30 lb ft). 3. Install the EGR coolant pipe. 4. Install the EGR coolant pipe bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5623 Tighten Tighten the bolts to 25 N.m (18 lb ft). 5. Install the EGR coolant pipe hose. 6. Position the EGR coolant pipe hose clamp. 7. Lubricate a NEW washer with diesel fuel. 8. Install the fuel injection control module upper banjo bolt and the NEW washer. Tighten Tighten the bolt to 34 N.m (25 lb ft). 9. Connect the fuel feed line quick connect fitting. 10. Install the water outlet tube. 11. Prime the fuel system. Refer to Fuel System Priming. 12. Start the engine. If the engine stalls, repeat the above step. 13. Once the engine starts, inspect for fuel leaks. Fuel Hose/Pipes Replacement - (Pickup) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (PICKUP) REMOVAL PROCEDURE 1. Disconnect the fuel feed and return lines. 2. Remove the fuel line bracket nut. 3. Remove the fuel line bracket from the stud. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5624 5. Remove the fuel bundle clips (2) from the transmission brackets (1). 6. Disconnect the chassis harness from the retaining clips. 7. Remove the fuel system cooler, if necessary. 8. Disconnect the fuel feed and return lines from the fuel tank lines. 9. Remove the fuel bundle nuts from the chassis. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5625 10. Loosen the electronic brake control module (EBCM) bracket bolts (4). 11. Allow the EBCM to remain loose in order to allow fuel pipe clearance. 12. Remove the fuel bundle using the following procedure: 12.1. Guide the fuel bundle pipes towards the rear of the vehicle to clear the engine. 12.2. Lower the fuel bundle while moving it forward and out. INSTALLATION PROCEDURE 1. Install the fuel pipe bundle using the following procedure: 1.1. Install the fuel bundle to the chassis by guiding the pipes towards the rear of vehicle. 1.2. Lift the fuel pipes, while guiding the forward portion of the pipes up towards the engine connections. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel bundle nuts to the chassis. Tighten Tighten the nuts to 16 N.m (12 lb ft). 3. Connect the fuel feed and return lines to the fuel tank lines. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5626 4. Install the fuel system cooler, if necessary. 5. Connect the fuel bundle clips (2) to the transmission brackets (1). 6. Tighten the EBCM bracket bolts (4). Tighten Tighten the bolts to 25 N.m (18 lb ft). 7. Lower the vehicle. 8. Install the fuel line bracket to the stud. 9. Install the fuel line bracket nut. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5627 Tighten Tighten the nut to 16 N.m (12 lb ft). 10. Connect the fuel feed and return lines. 11. Prime the fuel system. Refer to Fuel System Priming. 12. Start the engine. If the engine stalls, repeat the above step. 13. Once the engine starts, inspect for fuel leaks. Fuel Hose/Pipes Replacement - (Cab/Chassis) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (CAB/CHASSIS) REMOVAL PROCEDURE 1. Disconnect the fuel feed and return lines. 2. Remove the fuel line bracket nut. 3. Remove the fuel line bracket from the stud. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Remove the fuel bundle clips (2) from the transmission brackets (1). 6. Disconnect the chassis harness from the retaining clips. 7. Remove the fuel system cooler, if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5628 8. Disconnect the fuel feed and return lines from the fuel tank lines. 9. Remove the fuel bundle nuts from the chassis. 10. Loosen the electronic brake control module (EBCM) bracket bolts (4). 11. Allow the EBCM to remain loose in order to allow fuel pipe clearance. 12. Remove the fuel bundle using the following procedure: 12.1. Guide the fuel bundle pipes towards the rear of vehicle to clear the engine. 12.2. Lower the fuel bundle while moving it foreword and out. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5629 1. Install the fuel pipe bundle using the following procedure: 1.1. Install the fuel bundle to the chassis by guiding the pipes towards the rear of vehicle. 1.2. Lift the fuel pipes, while guiding the forward portion of the pipes up towards the engine connections. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel bundle nuts to the chassis. Tighten Tighten the nuts to 16 N.m (12 lb ft). 3. Connect the fuel feed and return lines to the fuel tank lines. 4. Install the fuel system cooler, if necessary. 5. Connect the fuel bundle clips (2) to the transmission brackets (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5630 6. Tighten the EBCM bracket bolts (4). Tighten Tighten the bolts to 25 N.m (18 lb ft). 7. Lower the vehicle. 8. Install the fuel line bracket to the stud. 9. Install the fuel line bracket nut. Tighten Tighten the nut to 16 N.m (12 lb ft). 10. Connect the fuel feed and return lines. 11. Prime the fuel system. Refer to Fuel System Priming. 12. Start the engine. If the engine stalls, repeat the above step. 13. Once the engine starts, inspect for fuel leaks. Fuel Hose/Pipes Replacement - (Cab/Chassis - W/Balance Pump) FUEL HOSE/PIPES REPLACEMENT - CHASSIS (CAB/CHASSIS W/BALANCE PUMP) REMOVAL PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5631 1. Remove the front and auxiliary fuel tanks. 2. Disconnect the pressure balance pump electrical connector. 3. Remove the fuel bundle nuts. 4. Remove the fuel bundle. INSTALLATION PROCEDURE 1. Install the fuel bundle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel bundle nuts. Tighten Tighten the nuts to 16 N.m (12 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5632 3. Connect the pressure balance pump electrical connector. 4. Install the front and auxiliary fuel tanks. Fuel Hose Replacement - Fuel Injection Pump to Fuel Feed Block FUEL HOSE REPLACEMENT - FUEL INJECTION PUMP TO FUEL FEED BLOCK REMOVAL PROCEDURE 1. Remove the water outlet. 2. Remove the air intake tube. 3. Reposition the fuel hose clamps (1) at the return/feed line as required. 4. Disconnect the fuel hoses from the return/feed line as required. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5633 5. Reposition the fuel hose clamps (1) at the injection pump as required. 6. Disconnect the fuel hoses (2, 3) from the injection pump as required. 7. Remove the fuel hoses from the vehicle as required. REMOVAL PROCEDURE 1. Install the fuel hoses to the vehicle as required. 2. Connect the fuel hoses (2, 3) to the injection pump as required. 3. Position the fuel hose clamps (1) at the injection pump as required. 4. Connect the fuel hoses to the return/feed line as required. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5634 5. Position the fuel hose clamps (1) at the return/feed line as required. 6. Install the air intake tube. 7. Install the water outlet. 8. Prime the fuel system. Refer to Fuel System Priming. 9. Start the engine. If the engine stalls, repeat the above step. 10. Once the engine starts, inspect for fuel leaks. Fuel Hose Replacement - Fuel Filter/Heater to Fuel Feed Block FUEL HOSE REPLACEMENT - FUEL FILTER/HEATER ELEMENT HOUSING TO FUEL FEED BLOCK REMOVAL PROCEDURE 1. Reposition the hose clamps at the fuel filter and the return line. 2. Remove the fuel hose (1) from the fuel filter housing and the return line. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5635 1. Install the fuel hose (1) to the fuel filter housing and return line. 2. Position the hose clamps at the fuel filter and the return line. 3. Prime the fuel system. Refer to Fuel System Priming. 4. Start the engine. If the engine stalls, repeat the above step. 5. Once the engine starts, inspect for fuel leaks. Fuel Feed and Fuel Return Pipe Purge Procedure FUEL FEED AND FUEL RETURN PIPE PURGE PROCEDURE 1. Pump the primer located on top of the fuel filter 30 times or until stiff. 2. Attempt to start and run the engine. If the engine does not start, repeat step 1. 3. Allow to run for 5 minutes at idle. 4. Check for fuel leaks. 5. Clear all engine diagnostic trouble codes (DTCs). Fuel Rail Fuel Feed Pipe Replacement - Right FUEL RAIL FUEL FEED PIPE REPLACEMENT - RIGHT REMOVAL PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5636 1. Remove the engine wiring harness. 2. Remove the water outlet. 3. Remove the exhaust gas recirculation (EGR) cooler tube. 4. Disconnect the right fuel rail feed pipe fittings (1, 3). 5. Remove the fuel rail pipe clamp bolts (2). 6. Remove the right fuel rail feed pipe. REMOVAL PROCEDURE 1. Install the right fuel rail feed pipe. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5637 2. Install the fuel rail pipe clamp bolts (2). Tighten Tighten the bolts to 25 N.m (18 lb ft). 3. Connect the right fuel rail feed pipe fittings (1, 3). Tighten Tighten the fittings to 41 N.m (30 lb ft). 4. Install the EGR cooler tube. 5. Install the water outlet. 6. Install the engine wiring harness. 7. Prime the fuel system. Refer to Fuel System Priming. 8. Start the engine. If the engine stalls, repeat the above step. 9. Once the engine starts, inspect for fuel leaks. Fuel Rail Fuel Feed Pipe Replacement - Left FUEL RAIL FUEL FEED PIPE REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the water outlet. 2. Reposition the return line hose clamps at the return line and injection pump. 3. Remove the hose (3) from the return line and injection pump. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5638 4. Disconnect the left fuel rail feed pipe fittings (1). 5. Remove the left fuel rail feed pipe. REMOVAL PROCEDURE 1. Install the left fuel rail feed pipe. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5639 2. Connect the left fuel rail feed pipe fittings (1). Tighten Tighten the fittings to 41 N.m (30 lb ft). 3. Install the hose (3) to the return line and injection pump. 4. Position the return line hose clamps at the return line and injection pump. 5. Install the water outlet. 6. Prime the fuel system. Refer to Fuel System Priming. 7. Start the engine. If the engine stalls, repeat the above step. 8. Once the engine starts, inspect for fuel leaks. Fuel Injector Feed Pipes Replacement - Right FUEL INJECTOR FEED PIPES REPLACEMENT - RIGHT REMOVAL PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5640 1. Remove the air cleaner outlet duct. 2. Loosen the charged air cooler outlet duct to intake hose clamp. IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting. 3. Remove the charged air cooler outlet duct from the intake. 4. Remove the fuel filter. 5. Remove the fuel rail pressure sensor. 6. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris. 7. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal. NOTE: DO NOT use compressed air to clean debris from the fuel injector inlet after the fuel line is removed. Using compressed air can allow debris to enter the fuel injector inlet and damage the fuel injector. 8. Remove the fuel injector pipes. INSTALLATION PROCEDURE NOTE: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak. - Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5641 1. Install the fuel injector pipes. Tighten Tighten the fittings to 41 N.m (30 lb ft). 2. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fittings to prevent moisture and debris from collecting between the line and fitting. 3. Install the fuel rail pressure sensor. 4. Install the fuel filter. 5. Installer the charged air cooler outlet duct to the intake. 6. Tighten the charged air cooler outlet duct to intake hose clamp. Tighten Tighten the clamp to 6 N.m (53 lb in). 7. Install the air cleaner outlet duct. 8. Prime the fuel system. Refer to Fuel System Priming. 9. Start the engine. If the engine stalls, repeat the above step. 10. Once the engine starts, inspect for fuel leaks. Fuel Injector Feed Pipes Replacement - Left FUEL INJECTOR FEED PIPES REPLACEMENT - LEFT REMOVAL PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5642 1. Remove the intake manifold cover. 2. Drain the cooling system. 3. Disconnect the negative battery cable. IMPORTANT: After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects. 4. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting. 5. Remove the charged air cooler inlet duct connector (4) from the turbocharger. 6. Remove the battery cable to generator nut. 7. If equipped, remove the battery cable to auxiliary generator nut. 8. Remove the battery cable harness clip from the bracket. 9. Remove the battery cable junction block bolt (1) from the power steering pump. 10. Move and secure the battery cables out of the way. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5643 11. Disconnect the fuel lines. 12. Remove the fuel line bracket nut. 13. Remove the fuel line bracket from the stud. 14. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors. 15. Open the harness clip (2). 16. Remove the main engine electrical harness connectors. 17. Remove the engine harness main electrical connectors bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5644 18. Disconnect the barometric sensor electrical connector. 19. Remove the engine harness main connector bracket bolts. 20. Remove the water outlet tube. 21. Remove the auxiliary generator, if equipped. 22. Disconnect the glow plug controller electrical connector. 23. Disconnect the glow plug controller battery feed electrical connector (1). 24. Remove the positive crankcase ventilation (PCV) hose/pipe. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5645 25. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris. 26. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal. NOTE: DO NOT use compressed air to clean debris from the fuel injector inlet after the fuel line is removed. Using compressed air can allow debris to enter the fuel injector inlet and damage the fuel injector. 27. Remove the left fuel injector pipes. INSTALLATION PROCEDURE NOTE: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak. - Refer to Fastener Notice in Service Precautions. 1. Install the fuel injector pipes. Tighten Tighten the fittings to 41 N.m (30 lb ft). 2. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fittings to prevent moisture and debris from collecting between the line and fitting. 3. Install the PCV hose/pipe. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5646 4. Connect the glow plug controller battery feed electrical connector (1). 5. Connect the glow plug controller electrical connectors. 6. Install the auxiliary generator, if equipped. 7. Install the water outlet tube. 8. Install the engine harness main connector bracket bolts. Tighten Tighten the bolts to 21 N.m (15 lb ft). 9. Connect the barometric sensor electrical connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5647 10. Install the engine harness main electrical connectors bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). 11. Connect the main engine electrical harness connectors. 12. Push down on the latches (1) in order to connect the connectors. 13. Close the harness clip (2). 14. Install the fuel line bracket from the stud. 15. Install the fuel line bracket nut. Tighten Tighten the nut to 21 N.m (15 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5648 16. Connect the fuel lines. 17. Position the generator positive cable. 18. Install the generator positive cable in the clip on the engine front cover. 19. Install the generator positive cable and nut to the generator. Tighten Tighten the nut to 9 N.m (80 lb in). 20. Install the battery positive cable junction block bracket and bolt (1) to the power steering bracket. Tighten Tighten the bolt to 9 N.m (80 lb in). 21. Remove the tape from the turbocharger openings. IMPORTANT: Lubricate the end of the duct prior to installation. 22. Install the charged air cooler inlet duct connector (4) to the turbocharger. 23. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1). Tighten Tighten the clamp to 6 N.m (53 lb in). 24. Install the intake manifold cover. 25. Fill the cooling system. 26. Connect the negative battery cable. 27. Prime the fuel system. Refer to Fuel System Priming. 28. Start the engine. If the engine stalls, repeat the above step. 29. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Feed Pipe Replacement > Page 5649 Fuel System Priming Fuel system priming procedures can be found under Fuel Delivery and Air Induction system service procedures. See: Service and Repair/Fuel System Priming Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Filler Hose Replacement (Cab Chassis) Fuel Filler Hose: Service and Repair Fuel Filler Hose Replacement (Cab Chassis) FUEL FILLER HOSE REPLACEMENT (CAB/CHASSIS) REMOVAL PROCEDURE 1. Relieve the fuel system pressure. 2. Disconnect the fuel feed and pressure balance rear lines. 3. Loosen the fuel fill and vent hose clamps (1, 2) at the tank. 4. Remove the fuel fill and vent hoses from the tank. 5. Cap the fuel and vent holes in the fuel tank in order to prevent possible fuel system contamination. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Filler Hose Replacement (Cab Chassis) > Page 5655 1. Remove the caps from the fuel and vent holes in the fuel tank. 2. Install the fuel fill and vent hoses to the tank. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the fuel fill and vent hose clamps (1, 2) at the tank. Tighten Tighten the clamp to 2.5 N.m (22 lb in). 4. Connect the fuel feed and pressure balance rear lines. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Filler Hose Replacement (Cab Chassis) > Page 5656 Fuel Filler Hose: Service and Repair Fuel Filler Hose Replacement (Pickup) FUEL FILLER HOSE REPLACEMENT (PICKUP) REMOVAL PROCEDURE 1. Remove the fuel tank filler housing to body screws (1) and retainer (2). 2. Remove the fuel tank filler pipe housing to fuel tank fill pipe screws. 3. Remove the fuel tank filler housing. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Filler Hose Replacement (Cab Chassis) > Page 5657 5. Remove the fuel tank ground strap bolt (1). 6. Remove the chassis harness ground strap (2) and fuel tank ground strap (3). 7. Remove the rear axle vent hose from the clip on the fuel fill pipe bracket. 8. Loosen the fuel tank vent hose and fill hose clamps (1, 2). 9. Remove the vent hose from the tank. 10. Remove the fill hose from the tank and the vehicle. 11. Cap the opening on the fuel tank in order to prevent possible fuel system contamination. INSTALLATION PROCEDURE 1. Remove the cap from the opening on the fuel tank. 2. Install the fill hose to the vehicle and tank. 3. Install the vent hose to the tank. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the fuel tank vent hose and fill hose clamps (1, 2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Filler Hose Replacement (Cab Chassis) > Page 5658 Tighten Tighten the clamp to 2.5 N.m (22 lb in). 5. Install the rear axle vent hose to the clip on the fuel fill pipe bracket. 6. Position the chassis harness ground strap (2) and fuel tank ground strap (3). 7. Install the ground strap anti-rotation tab into the frame hole. 8. Install the fuel tank ground strap bolt (1). Tighten Tighten the bolt to 9 N.m (80 lb in). 9. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Filler Hose Replacement (Cab Chassis) > Page 5659 10. Install the fuel tank filler housing. 11. Install the fuel tank filler housing to fuel tank fill pipe screws. Tighten Tighten the screws to 2.3 N.m (20 lb in). 12. Install the fuel tank filler housing to body screws (1) and retainer (2). Tighten Tighten the screws to 2.3 N.m (20 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications Fuel Gauge Sender: Specifications FUEL LEVEL SPECIFICATIONS Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications > Page 5663 The values in the table are approximate values based on information obtained from properly operating vehicles. Actual results may vary slightly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications > Page 5664 Fuel Gauge Sender: Locations Fuel Tank - Primary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications > Page 5665 Fuel Tank - Secondary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications > Page 5666 Fuel Gauge Sender: Diagrams Fuel Level Sensor - Primary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications > Page 5667 Fuel Level Sensor - Secondary W/Dual Tanks Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications > Page 5668 Fuel Level Sensor - Primary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications > Page 5669 Fuel Level Sensor - Secondary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications > Page 5670 Fuel Gauge Sender: Description and Operation FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The engine control module (ECM) sends the fuel level information via the class 2 circuit to the instrument panel cluster (IPC). This information is used for the instrument panel (I/P) fuel gage and the low fuel warning indicator, if applicable. The ECM also monitors the fuel level input for various diagnostics. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications > Page 5671 Fuel Gauge Sender: Service and Repair FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel level sensor electrical connector (1). 3. Remove the sensor retaining clip (3). 4. Squeeze the locking tangs (2) and remove the fuel level sensor. INSTALLATION PROCEDURE 1. Install the fuel level sensor. 2. Install the sensor retaining clip (3). 3. Connect the sensor electrical connector (1). 4. Install the sending unit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Vent: > 05-06-04-008A > Apr > 05 > Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set Fuel Tank Vent: Customer Interest Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set Bulletin No.: 05-06-04-008A Date: April 14, 2005 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P1172 or P2636, Fuel Gauge Reads Empty, Service Engine Soon (SES) Light On (Relocate Auxiliary Fuel Tank Vent Hose) Models: 2001-2005 Chevrolet Silverado (Cab Chassis Models Only) 2001-2005 GMC Sierra (Cab Chassis Models Only) with Auxiliary Fuel Tank Supercede: This bulletin is being revised to clarify the difference between the auxiliary fuel tank balance hose and vent hose. Please discard Corporate Bulletin Number 05-06-04-008 (Section 06 Engine/Propulsion System). Condition Some customers may comment that the SES light comes on and the fuel gauge reads empty. when This may occur when the vehicle is parked on an incline with the engine running. Diagnosis with a scan tool may reveal a DTC P1172 and/or P2636. Cause Important: A similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. The auxiliary fuel tank vent hose is located in the same "T" connection on the main tank vent hose as the auxiliary tank balance hose. During fuel transfer, the fuel is pumped out of the auxiliary tank to the main tank via the balance hose. The fuel is then sucked back into the auxiliary tank via the vent hose rather then dumping the fuel into the main tank. When the Powertrain Control Module (PCM) does not detect a fluid level transfer between the main tank and the auxiliary tank, the PCM shuts off the auxiliary tank pump and the fuel gauge goes to empty. Correction Follow the service procedure below to correct this condition. 1. Depending on the body upfitter, it may be necessary to raise the vehicle in order to gain access to the auxiliary tank balance hose. 2. Depending on the body upfitter, it may be necessary to remove the left rear tire/wheel assemblies in order to gain access to the auxiliary tank balance hose. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Vent: > 05-06-04-008A > Apr > 05 > Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set > Page 5680 3. Locate the auxiliary fuel tank vent hose. The vent hose is the smaller diameter of the two hoses that comes from the auxiliary fuel tank and feeds into the main tank vent hose. 4. Disconnect the auxiliary tank vent hose from the main tank vent hose connection. 5. Install the cap supplied with kit, P/N 15213990, to the main tank vent hose connector where the auxiliary tank vent hose was just removed. 6. Locate the section of vent hose on the main tank between the fuel filler neck and the metal pipe. The smaller of the two hoses on the filler neck. 7. Cut the main tank vent hose between the filler neck and the metal pipe using an appropriate cutting tool. 8. Install the "T" and the two hose clamps supplied with kit, P/N 15213990, into the main tank vent hose. Tighten Tighten the hose clamps to 2.5 N.m (22 lb in). 9. Install the new auxiliary tank vent hose and clamp supplied with kit, P/N 15213990, to the "T" that was just installed. Tighten Tighten the hose clamp to 2.5 N.m (22 lb in). 10. Connect the new vent hose to the original auxiliary tank hose. 11. Secure the newly installed vent hose and the original auxiliary tank vent hose with plastic ties supplied in kit, P/N 15213990. 12. If necessary, reinstall the left rear tires/wheels assemblies. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Vent: > 05-06-04-008A > Apr > 05 > Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set > Page 5681 13. If necessary, lower the vehicle. 14. Using a scan tool, clear the DTCs. 15. Start the vehicle and inspect for leaks. Important: Advise the customer that a similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Vent: > 05-06-04-008A > Apr > 05 > Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set Fuel Tank Vent: All Technical Service Bulletins Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set Bulletin No.: 05-06-04-008A Date: April 14, 2005 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P1172 or P2636, Fuel Gauge Reads Empty, Service Engine Soon (SES) Light On (Relocate Auxiliary Fuel Tank Vent Hose) Models: 2001-2005 Chevrolet Silverado (Cab Chassis Models Only) 2001-2005 GMC Sierra (Cab Chassis Models Only) with Auxiliary Fuel Tank Supercede: This bulletin is being revised to clarify the difference between the auxiliary fuel tank balance hose and vent hose. Please discard Corporate Bulletin Number 05-06-04-008 (Section 06 Engine/Propulsion System). Condition Some customers may comment that the SES light comes on and the fuel gauge reads empty. when This may occur when the vehicle is parked on an incline with the engine running. Diagnosis with a scan tool may reveal a DTC P1172 and/or P2636. Cause Important: A similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. The auxiliary fuel tank vent hose is located in the same "T" connection on the main tank vent hose as the auxiliary tank balance hose. During fuel transfer, the fuel is pumped out of the auxiliary tank to the main tank via the balance hose. The fuel is then sucked back into the auxiliary tank via the vent hose rather then dumping the fuel into the main tank. When the Powertrain Control Module (PCM) does not detect a fluid level transfer between the main tank and the auxiliary tank, the PCM shuts off the auxiliary tank pump and the fuel gauge goes to empty. Correction Follow the service procedure below to correct this condition. 1. Depending on the body upfitter, it may be necessary to raise the vehicle in order to gain access to the auxiliary tank balance hose. 2. Depending on the body upfitter, it may be necessary to remove the left rear tire/wheel assemblies in order to gain access to the auxiliary tank balance hose. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Vent: > 05-06-04-008A > Apr > 05 > Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set > Page 5687 3. Locate the auxiliary fuel tank vent hose. The vent hose is the smaller diameter of the two hoses that comes from the auxiliary fuel tank and feeds into the main tank vent hose. 4. Disconnect the auxiliary tank vent hose from the main tank vent hose connection. 5. Install the cap supplied with kit, P/N 15213990, to the main tank vent hose connector where the auxiliary tank vent hose was just removed. 6. Locate the section of vent hose on the main tank between the fuel filler neck and the metal pipe. The smaller of the two hoses on the filler neck. 7. Cut the main tank vent hose between the filler neck and the metal pipe using an appropriate cutting tool. 8. Install the "T" and the two hose clamps supplied with kit, P/N 15213990, into the main tank vent hose. Tighten Tighten the hose clamps to 2.5 N.m (22 lb in). 9. Install the new auxiliary tank vent hose and clamp supplied with kit, P/N 15213990, to the "T" that was just installed. Tighten Tighten the hose clamp to 2.5 N.m (22 lb in). 10. Connect the new vent hose to the original auxiliary tank hose. 11. Secure the newly installed vent hose and the original auxiliary tank vent hose with plastic ties supplied in kit, P/N 15213990. 12. If necessary, reinstall the left rear tires/wheels assemblies. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Vent: > 05-06-04-008A > Apr > 05 > Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set > Page 5688 13. If necessary, lower the vehicle. 14. Using a scan tool, clear the DTCs. 15. Start the vehicle and inspect for leaks. Important: Advise the customer that a similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair Fuel Tank Unit: Service and Repair Fuel Sender Assembly Replacement Tool Required J45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. 2. Disconnect the fuel lines from the sending unit. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 3. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. 4. Remove the sending unit and seal. Discard the seal. 5. Clean the sending unit sealing surfaces. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Page 5692 Important: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. Check the lock ring for flatness. 6. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 7. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 8. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install the sending unit and a NEW seal. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Page 5693 Important: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 2. Use the J 45722 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction. 3. Connect the fuel lines to the sending unit. 4. Install the fuel tank. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations Fuel Temperature Sensor: Locations Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 5697 Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 5698 Fuel Temperature Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 5699 Fuel Temperature Sensor: Service and Repair FUEL RAIL TEMPERATURE (FRT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold cover. IMPORTANT: After removing the charged air cooler duct, cover the turbocharger openings with tape in order to prevent entry of objects. 2. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting. 3. Remove the charged air cooler inlet duct connector (4) from the turbocharger. 4. Disconnect the fuel temperature sensor electrical connector. 5. Remove the fuel temperature sensor. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 5700 1. Install the fuel temperature sensor. Tighten Tighten the sensor to 22 N.m (16 lb ft). 2. Connect the fuel temperature sensor electrical connector. 3. Remove the tape from the turbocharger openings. 4. Install the charged air cooler inlet duct connector (4) to the turbocharger. 5. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1). Tighten Tighten the clamp to 6 N.m (53 lb in). 6. Install the intake manifold cover. 7. Prime the fuel system. Refer to Fuel System Priming. 8. Start the engine. If the engine stalls, repeat the above step. 9. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations FUEL PUMP RELAY - SECONDARY (Vehicles with Dual Tanks Only) Fuel Pump Relay-Secondary-With Dual Tanks The Fuel Pump Relay - Secondary is attached to the Underhood Fuse Block Bracket. The Underhood Fuse Block is located at the left side of the engine compartment, to the rear of the battery. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5709 Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5710 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SYSTEM DESCRIPTION The accelerator pedal position (APP) system along with the vehicle electronics and components is used to calculate and control the amount of acceleration and deceleration via fuel injector control. This eliminates the need for a mechanical cable attachment from the accelerator pedal to a throttle body. The APP system includes, but is not limited to, the following components : - The accelerator pedal position (APP) sensor assembly - The engine control module (ECM) Accelerator Pedal Position (APP) Sensor The accelerator pedal position (APP) sensor is mounted on the accelerator pedal control assembly. The sensor is made up of 3 individual sensors within one housing. Three separate signal, low reference, and 5-volt reference circuits are used in order to interface the accelerator pedal sensor assembly with the ECM. Each sensor has a unique functionality to determine pedal position. The ECM uses the APP sensor to determine the amount of acceleration or deceleration desired by the person driving the vehicle. The APP sensor 1 voltage should increase as the accelerator pedal is depressed, from below 1.0 volt at 0 pedal travel to above 2 volts at 100 percent pedal travel. APP sensor 2 voltage should decrease from above 4 volts at 0 pedal travel to below 3.0 volts at 100 percent pedal travel. APP sensor 3 voltage should decrease from above 3.8 volts at 0 percent pedal travel to below 3.3 volts at 100 percent pedal travel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5711 Accelerator Pedal Position Sensor: Service and Repair ACCELERATOR PEDAL POSITION (APP) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector. 3. Reposition the carpet to access the lower nut. 4. Remove the accelerator pedal nuts. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5712 1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Service Precautions. 2. Install the accelerator pedal nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Connect the APP sensor electrical connector. 4. Reposition the carpet. 5. Install the CPA retainer. 6. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 7. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle and a wide open throttle (WOT). 8. Verify that the vehicle meets the following conditions: - The vehicle is not in a reduced engine power mode. - The ignition is ON. - The engine is OFF. 9. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Mass Air Flow (MAF) Sensor: Locations Right Side Of The Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 5716 Right Side Of Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 5717 Intake Air Temperature (IAT)/Mass Airflow (MAF) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 5718 Mass Air Flow (MAF) Sensor: Service and Repair MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector (1). 2. Remove the MAF/IAT sensor TORX(R) screws. 3. Remove the MAF/IAT sensor (1). INSTALLATION PROCEDURE 1. Install the MAF/IAT sensor (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 5719 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the MAF/IAT sensor TORX(R) screws. Tighten Tighten the screws to 8 N.m (70 lb in). 3. Connect the MAF/IAT sensor electrical connector (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations Fuel Temperature Sensor: Locations Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 5723 Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 5724 Fuel Temperature Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 5725 Fuel Temperature Sensor: Service and Repair FUEL RAIL TEMPERATURE (FRT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold cover. IMPORTANT: After removing the charged air cooler duct, cover the turbocharger openings with tape in order to prevent entry of objects. 2. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1). IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting. 3. Remove the charged air cooler inlet duct connector (4) from the turbocharger. 4. Disconnect the fuel temperature sensor electrical connector. 5. Remove the fuel temperature sensor. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 5726 1. Install the fuel temperature sensor. Tighten Tighten the sensor to 22 N.m (16 lb ft). 2. Connect the fuel temperature sensor electrical connector. 3. Remove the tape from the turbocharger openings. 4. Install the charged air cooler inlet duct connector (4) to the turbocharger. 5. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1). Tighten Tighten the clamp to 6 N.m (53 lb in). 6. Install the intake manifold cover. 7. Prime the fuel system. Refer to Fuel System Priming. 8. Start the engine. If the engine stalls, repeat the above step. 9. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations Turbo Boost Sensor: Locations Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Page 5730 Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Page 5731 Boost Pressure Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Page 5732 Turbo Boost Sensor: Service and Repair BOOST PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the right fuel rail fuel feed pipe. 2. Remove the boost sensor bracket bolt (1). 3. Remove the boost sensor and bracket. 4. Separate the boost sensor from the bracket. 5. Inspect the sensor seal for damage, replace as necessary. INSTALLATION PROCEDURE 1. Position the boost sensor onto the bracket. 2. Install the boost sensor and bracket. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the boost sensor bracket bolt (1). Tighten Tighten the bolt to 9 N.m (80 lb in). 4. Install the right fuel rail fuel feed pipe. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Intercooler Duct > Component Information > Service and Repair > Left Intercooler Duct: Service and Repair Left Charged Air Cooler Hoses/Pipes Replacement (Left) Removal Procedure 1. Remove the left wheelhouse panel. Important: After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects. 2. Loosen the left charged air cooler inlet duct connector to turbocharger clamp (1). 3. Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting. Remove the left charged air cooler inlet duct connector (4) from the turbocharger. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Intercooler Duct > Component Information > Service and Repair > Left > Page 5739 4. Working through the left wheelhouse, loosen the charged air cooler inlet duct clamp (3) at the charged air cooler. 5. Remove the left charged air cooler inlet duct. Installation Procedure 1. Important: Lubricate the end of the duct prior to installation. Working through the left wheelhouse, install the charged air cooler inlet duct. 2. Hand tighten the left charged air cooler inlet duct clamp (3) at the charged air cooler. 3. Important: Lubricate the end of the duct prior to installation. Install the left charged air cooler outlet duct to the intake. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Intercooler Duct > Component Information > Service and Repair > Left > Page 5740 4. Tighten the charged air cooler outlet duct to intake hose clamps. Tighten the clamps to 6 Nm (53 inch lbs.). 5. Install the left wheelhouse panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Intercooler Duct > Component Information > Service and Repair > Left > Page 5741 Intercooler Duct: Service and Repair Right Charged Air Cooler Hoses/Pipes Replacement (Right) Removal Procedure 1. Remove the right wheelhouse panel. Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting. 2. Loosen the charged air cooler outlet duct to intake hose clamp. 3. Remove the charged air cooler outlet duct from the intake. 4. Working through the right wheelhouse, loosen the charged air cooler outlet duct clamp (1) at the charged air cooler. 5. Remove the charged air cooler outlet duct. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Intercooler Duct > Component Information > Service and Repair > Left > Page 5742 Installation Procedure 1. Important: Lubricate the end of the duct prior to installation. Working through the right wheelhouse, install the charged air cooler outlet duct. 2. Hand tighten the charged air cooler outlet duct clamp (1) at the charged air cooler. 3. Important: Lubricate the end of the duct prior to installation. Install the charged air cooler outlet duct to the intake. Notice: Refer to Fastener Notice in Service Precautions. 4. Tighten the charged air cooler outlet duct to intake hose clamps. Tighten the clamps to 6 Nm (53 inch lbs.). 5. Install the right wheelhouse panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Locations Turbo Boost Sensor: Locations Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Locations > Page 5746 Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Locations > Page 5747 Boost Pressure Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Locations > Page 5748 Turbo Boost Sensor: Service and Repair BOOST PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the right fuel rail fuel feed pipe. 2. Remove the boost sensor bracket bolt (1). 3. Remove the boost sensor and bracket. 4. Separate the boost sensor from the bracket. 5. Inspect the sensor seal for damage, replace as necessary. INSTALLATION PROCEDURE 1. Position the boost sensor onto the bracket. 2. Install the boost sensor and bracket. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the boost sensor bracket bolt (1). Tighten Tighten the bolt to 9 N.m (80 lb in). 4. Install the right fuel rail fuel feed pipe. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Air Intake Tube > Component Information > Service and Repair Turbocharger Air Intake Tube: Service and Repair AIR INTAKE PIPE REPLACEMENT REMOVAL PROCEDURE 1. Remove the intake manifold cover. 2. Remove the air cleaner outlet duct. 3. Remove the positive crankcase ventilation (PCV) hose/pipe. 4. Disconnect the turbocharger electrical connector. Lift the metal retainer, in order to disconnect. 5. Remove the engine wire harness clamp bolt and reposition. IMPORTANT: The clamp for the air intake pipe uses reverse threads. 6. Loosen the air intake pipe to turbocharger clamp (1). 7. Remove the air intake pipe (2) from the turbocharger. INSTALLATION PROCEDURE 1. Clean the mating surfaces on the air intake pipe (2) and the turbocharger. 2. Align the air intake pipe (2) to the turbocharger. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The clamp for the air intake pipe uses reverse threads. 3. Tighten the air intake pipe to turbocharger clamp (1). Tighten Tighten the clamp to 4.6 N.m (41 lb in). 4. Install the engine wire harness clamp bolt. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Air Intake Tube > Component Information > Service and Repair > Page 5752 Tighten Tighten the bolt to 10 N.m (89 lb in). 5. Connect the turbocharger electrical connector. 6. Install the PCV hose/pipe. 7. Install the air cleaner outlet duct. 8. Install the intake manifold cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Oil Line, Turbocharger > Component Information > Technical Service Bulletins > Engine - Turbocharger Lubrication Issues Oil Line: Technical Service Bulletins Engine - Turbocharger Lubrication Issues INFORMATION Bulletin No.: 03-06-93-001D Date: October 09, 2008 Subject: Diagnostic Information on Turbocharger Malfunction Due to Lack of Engine Oil for LBZ, LB7, LLY or LMM Duramax(TM) Diesel Engine Models: 2001-2009 Chevrolet Silverado 2003-2009 Chevrolet Kodiak C4500-C5500 Series 2006-2009 Chevrolet Express 2001-2009 GMC Sierra 2003-2009 GMC TopKick C4500-C5500 Series 2006-2009 GMC Savana with 6.6L Duramax(TM) V8 Diesel Engine (VINs D, 1, 2, 6 RPOs LBZ, LB7, LLY, LMM) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 03-06-93-001C (Section 06 - Engine/Propulsion System). Notice: Before installing a new turbocharger, clean any debris or excessive oil from the charge air cooler and intake system in order to prevent damage to the new turbocharger or an engine overspeed condition. Spun Camshaft Bearing If a turbocharger performance concern is thought to be caused from a deficiency of engine oil, the camshaft bearing should be checked. The number 4 camshaft bearing bore feeds the turbocharger engine oil supply hose. If this camshaft bearing spins in the bore, the turbocharger will be deprived of engine oil. This will cause a performance concern with the turbocharger. Incorrect diagnosis of this condition will result in a repeat performance concern with the turbocharger. Camshaft Bearing Inspection If the turbocharger has to be replaced, perform the following procedure in order to verify the condition of the number 4 camshaft bearing before installing a new turbocharger. 1. Remove the turbocharger. Refer to Service Information (SI) procedures for Turbocharger Replacement. 2. Remove the turbocharger oil supply hose. 3. Visually inspect for correct alignment of the number 4 camshaft bearing oil hole (Refer to illustration callout 4) through the turbocharger oil supply hole in the block (Refer to illustration callout 1). The camshaft journal oil groove (Refer to illustration callout 3) should be visible through the camshaft bearing oil hole (Refer to illustration callout 4). 4. Turn the engine over by hand a 1/2 turn. The camshaft journal oil groove (Refer to illustration callout 3) should still be visible through the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Oil Line, Turbocharger > Component Information > Technical Service Bulletins > Engine - Turbocharger Lubrication Issues > Page 5757 camshaft bearing oil hole (Refer to illustration callout 4) as the engine is turned. 5. If the camshaft bearing (Refer to illustration callout 2) has spun, the camshaft bearing oil hole (Refer to illustration callout 4) will either not be visible at all or it will be misaligned with the turbocharger oil supply hole during the inspection procedure. In the event of a spun camshaft bearing, the engine must be replaced. Restricted Turbocharger Oil Supply Hose If a lack of oil is suspected, the turbocharger oil supply hose should also be checked for damage. The turbocharger oil feed line is a high pressure plastic tube that is protected by a stainless steel braided covering. If it is twisted at all or bent too far during turbocharger removal, the plastic line may fold and kink. The kink may cause an oil flow restriction. If the plastic pipe does kink, it will not return back to its normal size and shape. The damage may not be obvious upon inspection because the braided steel covering will hide the deformity. LB7 Turbocharger Replacement During turbocharger removal on the 6.6L LB7 engine, the turbocharger oil feed line can be pulled directly away from the turbocharger body in a perpendicular fashion. Care must be taken to avoid excessive bending of the line. LBZ, LLY or LMM Turbocharger Replacement During repairs on the 6.6L LBZ, LLY or LMM engine, the EGR cooler does not allow enough perpendicular movement of the line to clear the turbocharger for removal. However, the line can be pushed straight forward of the turbocharger with less risk of kinking the line. Assistance may be required to keep the lines clear of the turbocharger during removal or installation. Notice: Do not twist the turbocharger oil supply line. Twisting of the line will result in the collapse and deformation of the plastic line, restricting oil flow and causing turbocharger performance concerns. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Oil Line, Turbocharger > Component Information > Technical Service Bulletins > Page 5758 Oil Line: Service and Repair Turbocharger Oil Supply Hose Replacement Removal Procedure 1. Remove the turbocharger. 2. Remove the turbocharger oil feed pipe bolt. 3. Remove the oil feed pipe and washer. Installation Procedure 1. Important: Lubricate the NEW washer with diesel fuel before installing. Position the oil feed pipe and a NEW washer into place. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Oil Line, Turbocharger > Component Information > Technical Service Bulletins > Page 5759 2. Install the oil feed pipe bolt. Tighten the bolt to 34 Nm (25 ft. lbs.). 3. Install the turbocharger. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Right Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5764 Camshaft Position (CMP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Replacement CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the cooling fan pulley. 2. Remove the camshaft position (CMP) sensor bolt. 3. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Lubricate the CMP sensor O-ring with clean engine oil. 2. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the CMP sensor bolt. Tighten Tighten the bolt to 10 N.m (89 lb in). 4. Install the cooling fan pulley. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement > Page 5767 Camshaft Position Sensor: Service and Repair Camshaft Reluctor Replacement Camshaft Reluctor Replacement Removal Procedure Notice: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 1. Remove the engine front cover. 2. While holding the secondary oil pump shaft with a hex driver, remove the oil pump driven gear nut. 3. Remove the oil pump driven gear. 4. Important: DO NOT remove the reluctor from the oil pump drive gear. The reluctor is timed to the gear and once removed the correct timing will be lost. Remove the oil pump drive gear and crankshaft sensor reluctor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement > Page 5768 5. Remove the camshaft reluctor screws. 6. Remove the camshaft reluctor. 7. Clean and Inspect the camshaft reluctor for damage. Replace the reluctor if damage is found. Installation Procedure 1. Position the camshaft reluctor to the camshaft gear. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the camshaft reluctor bolts. Tighten the bolts to 9 Nm (80 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement > Page 5769 3. Important: Do not damage the teeth on the reluctor. Install the oil pump drive gear and reluctor to the crankshaft. 4. Install the oil pump driven gear. 5. While holding the secondary oil pump shaft with a hex driver, install the oil pump driven gear nut. Tighten the nut to 100 Nm (74 ft. lbs.). 6. Install the engine front cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Starter Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 5773 Right Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 5774 Crankshaft Position (CKP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 5775 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the right wheelhouse panel. 3. Disconnect the crankshaft position (CKP) sensor electrical connector. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. 6. If necessary, remove the CKP sensor spacer bolts. 7. If necessary, remove the CKP sensor spacer. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 5776 1. If necessary, lubricate a NEW CKP spacer O-ring with clean engine oil. 2. If necessary, install the NEW O-ring to the CKP sensor spacer. IMPORTANT: The crankshaft position sensor spacers are machined with different timing positions. However, if the crankshaft position sensor spacer requires replacement, replace with a grade "C" spacer. 3. If necessary, install the CKP sensor spacer. NOTE: Refer to Fastener Notice in Service Precautions. 4. If necessary, install the CKP sensor spacer bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). 5. Lubricate a NEW CKP sensor O-ring with clean engine oil. 6. Install the NEW O-ring to the CKP sensor. 7. Install the CKP sensor. 8. Install the CKP sensor bolt. Tighten Tighten the bolt to 10 N.m (89 lb in). 9. Connect the CKP sensor electrical connector. 10. Install the right wheelhouse panel. 11. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Testing and Inspection Ignition Relay: Testing and Inspection IGNITION RELAY DIAGNOSIS CIRCUIT DESCRIPTION The EDU/IGN 1 relay is normally an open relay. The relay armature is held in the open position by spring tension. When the ignition switch is turned to the Run or Start position, current will flow through the relay coil. A wire connected to the other end of the relay coil completes the path to ground through the engine control module (ECM). The electromagnetic field created by the relay coil overcomes the spring tension and moves the armature, allowing the contacts to close. The closed relay contacts allow current to flow from the battery to the following fuses: The ECM RPV fuse - The EDU fuse When the ignition switch is turned to the OFF position, the electromagnetic field collapses. This action allows the spring tension to move the armature away from the relay contacts, which interrupts current flow to the fuses. If the EDU/IGN 1 relay fails to close, the engine will crank but will not run. The class 2 communications will be available with the use of a scan tool. The EDU/IGN 1 relay table assumes that the vehicle battery is fully charged. TEST Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 5780 Steps 1-4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 5781 Steps 5-7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 5782 Steps 8-11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 5783 Steps 12-14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 5784 Steps 15-17 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 5785 Steps 18-22 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 5786 Steps 23-25 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection Ignition Relay: Testing and Inspection IGNITION RELAY DIAGNOSIS CIRCUIT DESCRIPTION The EDU/IGN 1 relay is normally an open relay. The relay armature is held in the open position by spring tension. When the ignition switch is turned to the Run or Start position, current will flow through the relay coil. A wire connected to the other end of the relay coil completes the path to ground through the engine control module (ECM). The electromagnetic field created by the relay coil overcomes the spring tension and moves the armature, allowing the contacts to close. The closed relay contacts allow current to flow from the battery to the following fuses: The ECM RPV fuse - The EDU fuse When the ignition switch is turned to the OFF position, the electromagnetic field collapses. This action allows the spring tension to move the armature away from the relay contacts, which interrupts current flow to the fuses. If the EDU/IGN 1 relay fails to close, the engine will crank but will not run. The class 2 communications will be available with the use of a scan tool. The EDU/IGN 1 relay table assumes that the vehicle battery is fully charged. TEST Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 5791 Steps 1-4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 5792 Steps 5-7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 5793 Steps 8-11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 5794 Steps 12-14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 5795 Steps 15-17 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 5796 Steps 18-22 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 5797 Steps 23-25 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Right Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5802 Camshaft Position (CMP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor Replacement CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the cooling fan pulley. 2. Remove the camshaft position (CMP) sensor bolt. 3. Remove the CMP sensor. INSTALLATION PROCEDURE 1. Lubricate the CMP sensor O-ring with clean engine oil. 2. Install the CMP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the CMP sensor bolt. Tighten Tighten the bolt to 10 N.m (89 lb in). 4. Install the cooling fan pulley. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement > Page 5805 Camshaft Position Sensor: Service and Repair Camshaft Reluctor Replacement Camshaft Reluctor Replacement Removal Procedure Notice: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 1. Remove the engine front cover. 2. While holding the secondary oil pump shaft with a hex driver, remove the oil pump driven gear nut. 3. Remove the oil pump driven gear. 4. Important: DO NOT remove the reluctor from the oil pump drive gear. The reluctor is timed to the gear and once removed the correct timing will be lost. Remove the oil pump drive gear and crankshaft sensor reluctor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement > Page 5806 5. Remove the camshaft reluctor screws. 6. Remove the camshaft reluctor. 7. Clean and Inspect the camshaft reluctor for damage. Replace the reluctor if damage is found. Installation Procedure 1. Position the camshaft reluctor to the camshaft gear. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the camshaft reluctor bolts. Tighten the bolts to 9 Nm (80 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position (CMP) Sensor Replacement > Page 5807 3. Important: Do not damage the teeth on the reluctor. Install the oil pump drive gear and reluctor to the crankshaft. 4. Install the oil pump driven gear. 5. While holding the secondary oil pump shaft with a hex driver, install the oil pump driven gear nut. Tighten the nut to 100 Nm (74 ft. lbs.). 6. Install the engine front cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Starter Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 5811 Right Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 5812 Crankshaft Position (CKP) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 5813 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the right wheelhouse panel. 3. Disconnect the crankshaft position (CKP) sensor electrical connector. 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. 6. If necessary, remove the CKP sensor spacer bolts. 7. If necessary, remove the CKP sensor spacer. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 5814 1. If necessary, lubricate a NEW CKP spacer O-ring with clean engine oil. 2. If necessary, install the NEW O-ring to the CKP sensor spacer. IMPORTANT: The crankshaft position sensor spacers are machined with different timing positions. However, if the crankshaft position sensor spacer requires replacement, replace with a grade "C" spacer. 3. If necessary, install the CKP sensor spacer. NOTE: Refer to Fastener Notice in Service Precautions. 4. If necessary, install the CKP sensor spacer bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). 5. Lubricate a NEW CKP sensor O-ring with clean engine oil. 6. Install the NEW O-ring to the CKP sensor. 7. Install the CKP sensor. 8. Install the CKP sensor bolt. Tighten Tighten the bolt to 10 N.m (89 lb in). 9. Connect the CKP sensor electrical connector. 10. Install the right wheelhouse panel. 11. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug > Component Information > Diagrams Glow Plug: Diagrams Glow Plug Controller - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug > Component Information > Diagrams > Page 5819 Glow Plug Controller - C2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug > Component Information > Diagrams > Page 5820 Glow Plug Controller - C2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug > Component Information > Diagrams > Page 5821 Glow Plug: Description and Operation GLOW PLUGS The glow plugs are 4.7.volt heaters in each of the cylinders that turn ON, then pulse-width modulated when the ignition switch is turned to the RUN position prior to starting the engine. They remain pulsing a short time after starting, then they are turned OFF. A Wait to Start lamp on the instrument panel provides information on engine starting conditions. The Wait to Start lamp will not illuminate during post-start glow plug operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug > Component Information > Service and Repair > Glow Plug Controller Glow Plug: Service and Repair Glow Plug Controller GLOW PLUG CONTROLLER REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the glow plug controller electrical connector. 3. Disconnect the glow plug controller battery feed electrical connector (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug > Component Information > Service and Repair > Glow Plug Controller > Page 5824 4. Remove the glow plug controller bolts. 5. Remove the glow plug controller. INSTALLATION PROCEDURE 1. Install the glow plug controller. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the glow plug controller bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). 3. Connect the glow plug controller battery feed electrical connector (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug > Component Information > Service and Repair > Glow Plug Controller > Page 5825 4. Connect the glow plug controller electrical connector. 5. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug > Component Information > Service and Repair > Glow Plug Controller > Page 5826 Glow Plug: Service and Repair Glow Plug - Bank 1 GLOW PLUG REPLACEMENT - BANK 1 REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left wheelhouse panel. 3. Remove the glow plug harness nut(s). 4. Remove the harness from the glow plug(s). 5. Remove the glow plug(s). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the glow plug(s). Tighten Tighten the plug to 18 N.m (13 lb ft). 2. Install the harness to the glow plug(s). 3. Install the glow plug harness nut(s). Tighten Tighten the nut to 1.7 N.m (15 lb in). 4. Install the left wheelhouse panel. 5. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug > Component Information > Service and Repair > Glow Plug Controller > Page 5827 Glow Plug: Service and Repair Glow Plug - Bank 2 GLOW PLUG REPLACEMENT - BANK 2 REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the right wheelhouse panel. 3. Remove the glow plug harness nut(s). 4. Remove the harness from the glow plug(s). 5. Remove the glow plug(s). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the glow plug(s). Tighten Tighten the plug to 18 N.m (13 lb ft). 2. Install the harness to the glow plug(s). 3. Install the glow plug harness nut(s). Tighten Tighten the nut to 1.7 N.m (15 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug > Component Information > Service and Repair > Glow Plug Controller > Page 5828 4. Install the right wheelhouse panel. 5. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Component Locations Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Component Locations > Page 5836 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5837 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement ^ Tools Required J 36850 Transjel Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission filter. 3. Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. Remove the reverse boost valve bushing retainer ring (2). 4. Remove the following from the reverse boost valve cylinder: ^ The reverse boost valve bushing ^ The reverse boost valve ^ The pressure regulator spring retainer ^ The pressure regulator spring ^ The pressure regulator valve ^ The reverse boost valve bushing Installation Procedure 1. Install the pressure regulator valve using J 36850. 2. Pre-assemble the following parts: ^ The reverse boost valve bushing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5838 ^ A new reverse boost valve ^ A new pressure regulator spring retainer ^ The added isolator pressure regulator spring ^ The pressure regulator spring 3. Install the pre-assembled parts into the pump bore. 4. Install the reverse boost valve bushing retainer ring while holding the reverse boost valve bushing in place. Ensure the retainer ring (2) is in the groove. 5. Install the transmission filter. 6. Fill the transmission to the proper level with Dexron® III transmission fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 5842 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure 1. Caution: Refer to SIR Caution in Service Precautions. Disable the SIR system. 2. Remove the body control module (BCM). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 5843 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the BCM. 6. Enable the SIR system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Electrical Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Electrical Specifications > Page 5848 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5849 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E Shift Solenoid: Diagrams Automatic Transmission - 4L80-E/4L85-E Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 5852 Shift Solenoid: Diagrams Automatic Transmission - Allison Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 5853 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 5854 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 5855 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 5856 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 5857 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5858 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. Remove the 1-2 accumulator, if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5859 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5860 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Notice: Refer to Fastener Notice in Service Precautions. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5861 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 5866 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5867 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Remove the transmission filter. 2. Disconnect the transmission harness 20-way connector (1) from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. 3. Important: Removal of the valve body is not necessary for the following procedure. Remove the 1-2 accumulator. Do not remove the spacer plate. 4. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ Torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 5. Remove the TCC PWM solenoid retainer. 6. Remove the TCC PWM solenoid in order to access one of the TCC solenoid bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5868 7. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 8. Remove the pressure control solenoid (377). 9. Remove the TCC solenoid bolts and the valve body bolts which retain the internal wiring harness. 10. Using J 28458 , release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the four tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5869 12. Inspect the TCC solenoid and wiring harness for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid bolts. ^ Tighten the control valve body bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid bolts to 11 Nm (97 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5870 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5871 ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector (1) to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 5876 Transfer Case Actuator: Service and Repair Transfer Case Encoder Motor Replacement Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Disconnect the encoder motor electrical connector. 4. Remove the encoder motor bolts. 5. Remove the encoder motor. 6. Remove the actuator insulator gasket. 7. If replacing the encoder motor, remove the locating pins from the old motor. Installation Procedure Important: ^ If the encoder motor is being replaced because it is defective, ensure that the transfer case is in the neutral position. Manually shift the unit at the shift shaft. Use a crescent wrench, if necessary. ^ If the encoder motor is being replaced, a new gasket will come with the encoder motor. DO NOT reuse the old gasket. ^ A NEW encoder motor does NOT come with locating pins. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 5877 1. Install the locating pins to the NEW encoder motor. 2. Position a NEW actuator insulator gasket to the transfer case. 3. Install the encoder motor. Notice: Refer to Fastener Notice in Service Precautions. 4. Install encoder motor bolts. ^ Tighten the bolts, in the sequence shown, to 20 Nm (15 ft. lbs.). 5. Connect the encoder motor electrical connector. Ensure that the retention clips activate. 6. Install the front propeller shaft. 7. Install the transfer case shield, if equipped. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Maintenance Indicator - A/T > Component Information > Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation PRNDL DISPLAY The IPC displays the selected gear position as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the gear position. The PRNDL display blanks if: - The IPC receives a class 2 message indicating the park position and the column park switch indicates a position other than park, open input. - The IPC detects a loss of class 2 communications with the PCM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Transmission Control Module Replacement Control Module: Service and Repair Transmission Control Module Replacement Transmission Control Module (TCM) Replacement Removal Procedure Important: ^ Remove any debris from the transmission control module(TCM) connector surfaces before servicing the TCM. Inspect the TCM module connector gaskets when diagnosing or replacing the TCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the TCM. ^ The ignition must be OFF when disconnecting or reconnecting power to the TCM. 1. Disconnect the negative battery cable. 2. Remove the TCM cover bolts (1) located on the left side of the radiator shroud. 3. Pull the cover and TCM up and away from the radiator shroud. 4. Push up on the retainers (1) in order to remove the TCM from the cover. 5. Disconnect the TCM electrical connectors (2) and remove the TCM from the vehicle. Installation Procedure 1. Connect the TCM electrical connectors (2) to the TCM. 2. Install the TCM to the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Transmission Control Module Replacement > Page 5892 3. Using the alignment tabs (1), install the cover and module to the radiator shroud. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the TCM cover bolts (1) to the radiator shroud. ^ Tighten the bolts to 9 Nm (80 inch lbs.). 5. Connect the negative battery cable. 6. Reprogram the TCM. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Transmission Control Module Replacement > Page 5893 Control Module: Service and Repair Transmission Control Module Reprogramming Procedures Transmission Control Module Reprogramming Procedures Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install new module before proceeding. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the Electronic Control Unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to Program/Reprogram. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Reconnect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the Electronic Control Unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to Program/Reprogram. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 02-04-21-006E > Jul > 06 > AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: Customer Interest AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 02-04-21-006E > Jul > 06 > AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 > Page 5903 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 02-04-21-006E > Jul > 06 > AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: All Technical Service Bulletins AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 02-04-21-006E > Jul > 06 > AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 > Page 5909 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 05-04-21-002 > Mar > 05 > Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 05-04-21-002 > Mar > 05 > Drivetrain - Transfer Case Control Module Replacement > Page 5914 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 05-04-21-002 > Mar > 05 > Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 05-04-21-002 > Mar > 05 > Drivetrain - Transfer Case Control Module Replacement > Page 5920 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > NVG 246-NP8 Control Module: Locations NVG 246-NP8 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > NVG 246-NP8 > Page 5923 Control Module: Locations NVG 263-NP1 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 5924 Control Module: Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 5925 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 5926 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 Control Module: Service and Repair NVG 246-NP8 Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install new module before proceeding. Before reprogramming close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to do so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Disconnect the scan tool from the vehicle and connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to Program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Reconnect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 5929 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 5930 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 5931 Control Module: Service and Repair NVG 263-NP1 Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 5932 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install a new module before proceeding. Before reprogramming, close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to do so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 5933 Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information about the type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Connect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information about the type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions Brake Switch - TCC: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5940 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5941 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5942 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5943 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5944 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5945 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5946 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5947 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5948 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5949 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5950 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5951 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5952 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5953 Brake Switch - TCC: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5954 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5955 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5956 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5957 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5958 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5959 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5960 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5961 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5962 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5963 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5964 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5965 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5966 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5967 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5968 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5969 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5970 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5971 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5972 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5973 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5974 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5975 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5976 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5977 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5978 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5979 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5980 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5981 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5982 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5983 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5984 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5985 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5986 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5987 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5988 Power, Ground and Brake Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Component Locations Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Component Locations > Page 5993 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 5994 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 5995 Fluid Pressure Sensor/Switch: Service and Repair Pressure Switch Manifold Replacement Removal Procedure 1. Important: Individual pressure switches cannot be replaced. When any pressure switch needs replacing, the entire assembly must be replaced. Important: The G solenoid has been removed for clarity. Remove the oil pan and suction filter. 2. Remove the two bolts (2). Remove the reverse signal tube (1). 3. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the internal wiring harness connector from the pressure switch assembly (2). 4. Remove five bolts (1). Remove the pressure switch assembly (2). Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 5996 1. Notice: Refer to Fastener Notice in Service Precautions. Place the new pressure switch manifold assembly (2) in position and install one bolt (1) in a recessed location to hold it into position. Start the remaining four bolts (1) in recessed locations and tighten the bolts by hand. Torque the bolts to 12 Nm (108 inch lbs.). 2. Connect the internal wiring harness connector to the pressure switch assembly. 3. Install the reverse signal tube (1). Install two bolts (2). ^ Tighten the bolts to 12 Nm (108 inch lbs.). 4. Install the oil pan and suction filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch: Testing and Inspection 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 6001 Steps 1-9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 6002 Tow/Haul Switch: Testing and Inspection 4L80-E/4L85-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between up shifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit checks are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 6003 Steps 1-9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start Transmission Position Switch/Sensor: Customer Interest A/T - Slow/No Gear Engagement/Engine No Start Bulletin No.: 02-07-30-011C Date: June 21, 2004 TECHNICAL Subject: Slow or No Engagement of Automatic Transmission, No Start, Blank PRNDL Display, Flashing PRNDL, DTC P0708, P0872, P0847, P0875, P1711, P1713 or U1000 Set (Diagnose Condition, Repair According to Procedure) Models: 2001-2004 Chevrolet Silverado 2001-2004 GMC Sierra with Allison(R) LCT1000 Automatic Transmission (RPO M74) and 6.6L Duramax(TM) Diesel Engine (RPO LB7) or 8.1L Gas Engine (RPO L18) Supercede: This bulletin is being revised to add model years and additional model information and add graphics. Please discard Corporate Bulletin Number 02-07-30-011B (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions. ^ The PRNDL display is flashing. ^ The engine will not start. ^ The "Service Engine Soon" Indicator lamp is illuminated. ^ The transmission does not shift properly. ^ The vehicle will not move, transmission will not engage. Cause Moisture contamination within the Park Neutral Position (PNP) Switch may cause this condition. This is sometimes referred to as the Neutral Start Back-up (NSBU) Switch. On a left turn, water spray from the left front tire is directed directly at this switch. Proper installation of the "Front Shield" and "Rear Shield" are essential for proper repairs. Technician Diagnosis This bulletin ONLY applies to vehicles equipped with a two connector PNP switch as shown above. A complete and through diagnosis must be performed by a qualified electrical technician to determine the cause and avoid needless replacement of good components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 6012 Important: The Transmission Control Module (TCM) and or the Pressure Switch Manifold (PSM) should NOT be replaced unless properly diagnosed. They are probably not the cause of the concern. It is often assumed the module is the cause of the concern when, in fact, it is another component or the wiring between the components that causes the concern. Important: Remember, everything starts with a properly operating Neutral Start Back Up (NSBU) switch. The NSBU switch has been incorporated into what is now called the Park Neutral Position (PNP) switch. If the PNP switch does not provide the proper voltage signal to the module indicating the transmission is in either Park or Neutral, the module will not allow the starter operation. After the engine is started, and the shift lever is moved to either Reverse or one of the drive positions, the range selected portion of the PNP switch portion provides a voltage input to the module as to what range the driver has manually selected for transmission operation. The module then controls pressures, shift points and other transmission functions based on the voltage input received from the range portion of the PNP switch. The technician may find one or more of the following conditions. The list of these conditions does not imply any type of frequency or order. They are random events and may occur in any order. ^ DTC P0708, Neutral start/backup (PNP or NSBU) switch ^ DTC P0847, Pressure Switch Manifold (PSM) ^ DTC P0872, Pressure Switch Manifold (PSM) ^ DTC P0875, Pressure Switch Manifold (PSM) ^ DTC P1711, Pressure Switch Manifold (PSM) ^ DTC P1713, Pressure Switch Manifold (PSM) ^ DTC U1000, Serial Data Communications ^ Blank PRNDL Display ^ Flashing PRNDL Display ^ Slow or No Engagement of Automatic Transmission Blank PRNDL Display A blank PRNDL display may indicate a condition with the PNP switch and/or one or more of the four signal circuits from the PNP to the TCM. 1. Pin A, Circuit 771 (BLK/WHT) 2. Pin B, Circuit 773 (GRA) 3. Pin C, Circuit 776 (WHT) 4. Pin D, Circuit 772 (YEL) Or, a blank PRNDL display may also occur if an out of line condition exists with the Serial Data Circuit (CKT 2470, yellow wire) from the TCM to Splice Pack 205. Diagnostic Tip 1. Connect the Tech 2(R) to the vehicle. 2. Power up the Tech 2(R). 3. Does the Tech 2(R) communicate with the TCM? If not, inspect the serial data circuit, CKT 2470 (Yellow wire), between the TCM and Splice Pack 205. Specifically inspect connector C106, a five terminal connector located below the left side underhood bussed electrical center, directly beneath the red battery cable terminal connection. Perform a mating terminal pull test on all of the terminals in this connector. Repair as required. 4. Observe the Gear Selected screen on the scan tool. The following values should be shown on the Tech 2(R) display and the vehicle's instrument panel cluster (if equipped with the I/P display). ^ "8" (shifter should be in the Park position) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 6013 ^ "7" (shifter should be in the Reverse position) ^ "5" (shifter should be in the Drive position) ^ "3" (shifter should be in the Third gear position) ^ "2" (shifter should be in the Second gear position) ^ "1" (shifter should be in the First gear position) ^ "0" (shifter should be in the Neutral Position) If the Gear Selected display does not match the shifter position in the vehicle, diagnose using one of the following methods. ^ Obtain a new PNP switch kit, P/N 29540479, from the Parts Department. ^ 0.1. Disconnect the wiring connector from the original transmission mounted PNP switch. ^ 0.2. Connect the new switch to the wiring connector. ^ 0.3. Return to Step # 4 above and observe the display as you rotate the switch. If all positions indicate properly, refer to the Correction section below. ^ Use the DTC P0708 diagnostic chart in Service Information (SI) under Transmission/Transaxle/Automatic Transmission - Allison. Reference SI Document ID # 769549 for the wiring schematic for this symptom. The PNP switch, as referenced in SI, is known as the NSBU switch in the Parts information. It is now serviced with a Park Neutral Position Switch Kit, P/N 29540479. Flashing PRNDL Display A flashing PRNDL display may be the result of incorrect sensor inputs or transmission abuse protection modes being received by the TCM. The following are some of these conditions: ^ The transfer case is/was in Neutral. ^ The transfer case is/was shifted into Neutral when the vehicle is moving. ^ A decrease of the input turbine speed was not detected when the gear selector was moved into any gear. ^ A low transmission fluid level. ^ A misadjusted PNP/NSBU switch. ^ Turbine input speed or output speed sensor failure. ^ Failures of the shift solenoids to route the transmission oil to the proper clutch assemblies within the transmission. ^ Failures of the transmission clutch packs (C1 or C5 for first gear, C3 or C5 for Reverse). ^ Failure to detect proper line pressures when a gear range is selected, which may be the result of normal maintenance such as a transmission fluid change having been completed, or the transmission pan was removed for a filter replacement or other type service. Transmission abuse protection modes are encountered when a customer performs one of the following types of maneuvers: ^ Shifting from Neutral to Drive/Reverse when the engine RPM is greater than 1400 RPM. ^ Shifting from Drive to Reverse when the throttle position (TPS) is greater than 25%, such as rocking the vehicle when stuck in an attempt to free the vehicle. ^ When the transmission output speed is greater than 300 RPM from attempted changes in direction such as Reverse to Drive, Drive to Reverse or Neutral to Reverse shifts. When the TCM encounters any one of the above conditions, the TCM will flash the PRNDL and default the transmission to Neutral. A flashing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 6014 PRNDL indicates something is/was incorrect. The transmission may need the attention of a qualified service technician. Correction 1. Disconnect the wiring harness from the PNP switch. 2. Disconnect the shift linkage/cable from the shift lever at the transmission. 3. With a wrench keeping the shift lever from rotating, remove the nut from the end of the selector shaft. 4. Use a file to remove any burrs or raised metal where the selector lever was seated against the shoulder of the selector shaft. Important: If the old PNP switch will not slide from the selector shaft without the effort, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 5. Remove the two bolts that attach the PNP switch and remove the switch by sliding it outward over the selector shaft. 6. Make sure the selector shaft is in the N (neutral) position (using a wrench on the selector shaft flats, rotate the shaft to its furthest clockwise position and then rotate counterclockwise two detents). Important: If the new PNP switch will not slide onto the selector shaft easily, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 7. Slide the new PNP switch over the selector shaft with the neutral assurance bracket 920 facing outward and maintaining the correct PNP switch orientation to the selector shaft. Install and hand tighten the two PNP switch attaching bolts so that the PNP switch and bracket may be rotated within the adjusting slots with some effort. 8. While holding the neutral assurance bracket in engagement with the PNP switch, tighten the two bolts that attach the PNP switch to the transmission case. Tighten Tighten the bolts to 27 N.m (20 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 6015 9. Remove and discard the neutral assurance bracket. Important: Installation of the front shield and rear shields are important. Without proper installation of the shield, a return repair is probable. Follow all directions as listed on the installation instructions sheet included in the Switch kit, P/N 29540479. 10. Fit the new shield onto the PNP switch so that it fits securely against the switch. Make sure this is done before reinstalling the shift lever. 11. Reinstall the shift lever. With a wrench keeping the shift lever from rotating, install the nut on the end of the selector shaft. Tighten. Tighten the nut to 24 N.m (18 lb ft). 12. Connect the wiring harness connectors to the PNP switch. 13. Attach the selector cable to the lever. Check and adjust if needed. 14. Go back to step 4 of the Diagnostics and insure the Tech 2 readings match the shift lever positions. Important: Clear all DTCs before returning the vehicle to the customer. 15. Return the vehicle to the customer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 6016 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Slow/No Gear Engagement/Engine No Start Bulletin No.: 02-07-30-011C Date: June 21, 2004 TECHNICAL Subject: Slow or No Engagement of Automatic Transmission, No Start, Blank PRNDL Display, Flashing PRNDL, DTC P0708, P0872, P0847, P0875, P1711, P1713 or U1000 Set (Diagnose Condition, Repair According to Procedure) Models: 2001-2004 Chevrolet Silverado 2001-2004 GMC Sierra with Allison(R) LCT1000 Automatic Transmission (RPO M74) and 6.6L Duramax(TM) Diesel Engine (RPO LB7) or 8.1L Gas Engine (RPO L18) Supercede: This bulletin is being revised to add model years and additional model information and add graphics. Please discard Corporate Bulletin Number 02-07-30-011B (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions. ^ The PRNDL display is flashing. ^ The engine will not start. ^ The "Service Engine Soon" Indicator lamp is illuminated. ^ The transmission does not shift properly. ^ The vehicle will not move, transmission will not engage. Cause Moisture contamination within the Park Neutral Position (PNP) Switch may cause this condition. This is sometimes referred to as the Neutral Start Back-up (NSBU) Switch. On a left turn, water spray from the left front tire is directed directly at this switch. Proper installation of the "Front Shield" and "Rear Shield" are essential for proper repairs. Technician Diagnosis This bulletin ONLY applies to vehicles equipped with a two connector PNP switch as shown above. A complete and through diagnosis must be performed by a qualified electrical technician to determine the cause and avoid needless replacement of good components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 6022 Important: The Transmission Control Module (TCM) and or the Pressure Switch Manifold (PSM) should NOT be replaced unless properly diagnosed. They are probably not the cause of the concern. It is often assumed the module is the cause of the concern when, in fact, it is another component or the wiring between the components that causes the concern. Important: Remember, everything starts with a properly operating Neutral Start Back Up (NSBU) switch. The NSBU switch has been incorporated into what is now called the Park Neutral Position (PNP) switch. If the PNP switch does not provide the proper voltage signal to the module indicating the transmission is in either Park or Neutral, the module will not allow the starter operation. After the engine is started, and the shift lever is moved to either Reverse or one of the drive positions, the range selected portion of the PNP switch portion provides a voltage input to the module as to what range the driver has manually selected for transmission operation. The module then controls pressures, shift points and other transmission functions based on the voltage input received from the range portion of the PNP switch. The technician may find one or more of the following conditions. The list of these conditions does not imply any type of frequency or order. They are random events and may occur in any order. ^ DTC P0708, Neutral start/backup (PNP or NSBU) switch ^ DTC P0847, Pressure Switch Manifold (PSM) ^ DTC P0872, Pressure Switch Manifold (PSM) ^ DTC P0875, Pressure Switch Manifold (PSM) ^ DTC P1711, Pressure Switch Manifold (PSM) ^ DTC P1713, Pressure Switch Manifold (PSM) ^ DTC U1000, Serial Data Communications ^ Blank PRNDL Display ^ Flashing PRNDL Display ^ Slow or No Engagement of Automatic Transmission Blank PRNDL Display A blank PRNDL display may indicate a condition with the PNP switch and/or one or more of the four signal circuits from the PNP to the TCM. 1. Pin A, Circuit 771 (BLK/WHT) 2. Pin B, Circuit 773 (GRA) 3. Pin C, Circuit 776 (WHT) 4. Pin D, Circuit 772 (YEL) Or, a blank PRNDL display may also occur if an out of line condition exists with the Serial Data Circuit (CKT 2470, yellow wire) from the TCM to Splice Pack 205. Diagnostic Tip 1. Connect the Tech 2(R) to the vehicle. 2. Power up the Tech 2(R). 3. Does the Tech 2(R) communicate with the TCM? If not, inspect the serial data circuit, CKT 2470 (Yellow wire), between the TCM and Splice Pack 205. Specifically inspect connector C106, a five terminal connector located below the left side underhood bussed electrical center, directly beneath the red battery cable terminal connection. Perform a mating terminal pull test on all of the terminals in this connector. Repair as required. 4. Observe the Gear Selected screen on the scan tool. The following values should be shown on the Tech 2(R) display and the vehicle's instrument panel cluster (if equipped with the I/P display). ^ "8" (shifter should be in the Park position) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 6023 ^ "7" (shifter should be in the Reverse position) ^ "5" (shifter should be in the Drive position) ^ "3" (shifter should be in the Third gear position) ^ "2" (shifter should be in the Second gear position) ^ "1" (shifter should be in the First gear position) ^ "0" (shifter should be in the Neutral Position) If the Gear Selected display does not match the shifter position in the vehicle, diagnose using one of the following methods. ^ Obtain a new PNP switch kit, P/N 29540479, from the Parts Department. ^ 0.1. Disconnect the wiring connector from the original transmission mounted PNP switch. ^ 0.2. Connect the new switch to the wiring connector. ^ 0.3. Return to Step # 4 above and observe the display as you rotate the switch. If all positions indicate properly, refer to the Correction section below. ^ Use the DTC P0708 diagnostic chart in Service Information (SI) under Transmission/Transaxle/Automatic Transmission - Allison. Reference SI Document ID # 769549 for the wiring schematic for this symptom. The PNP switch, as referenced in SI, is known as the NSBU switch in the Parts information. It is now serviced with a Park Neutral Position Switch Kit, P/N 29540479. Flashing PRNDL Display A flashing PRNDL display may be the result of incorrect sensor inputs or transmission abuse protection modes being received by the TCM. The following are some of these conditions: ^ The transfer case is/was in Neutral. ^ The transfer case is/was shifted into Neutral when the vehicle is moving. ^ A decrease of the input turbine speed was not detected when the gear selector was moved into any gear. ^ A low transmission fluid level. ^ A misadjusted PNP/NSBU switch. ^ Turbine input speed or output speed sensor failure. ^ Failures of the shift solenoids to route the transmission oil to the proper clutch assemblies within the transmission. ^ Failures of the transmission clutch packs (C1 or C5 for first gear, C3 or C5 for Reverse). ^ Failure to detect proper line pressures when a gear range is selected, which may be the result of normal maintenance such as a transmission fluid change having been completed, or the transmission pan was removed for a filter replacement or other type service. Transmission abuse protection modes are encountered when a customer performs one of the following types of maneuvers: ^ Shifting from Neutral to Drive/Reverse when the engine RPM is greater than 1400 RPM. ^ Shifting from Drive to Reverse when the throttle position (TPS) is greater than 25%, such as rocking the vehicle when stuck in an attempt to free the vehicle. ^ When the transmission output speed is greater than 300 RPM from attempted changes in direction such as Reverse to Drive, Drive to Reverse or Neutral to Reverse shifts. When the TCM encounters any one of the above conditions, the TCM will flash the PRNDL and default the transmission to Neutral. A flashing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 6024 PRNDL indicates something is/was incorrect. The transmission may need the attention of a qualified service technician. Correction 1. Disconnect the wiring harness from the PNP switch. 2. Disconnect the shift linkage/cable from the shift lever at the transmission. 3. With a wrench keeping the shift lever from rotating, remove the nut from the end of the selector shaft. 4. Use a file to remove any burrs or raised metal where the selector lever was seated against the shoulder of the selector shaft. Important: If the old PNP switch will not slide from the selector shaft without the effort, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 5. Remove the two bolts that attach the PNP switch and remove the switch by sliding it outward over the selector shaft. 6. Make sure the selector shaft is in the N (neutral) position (using a wrench on the selector shaft flats, rotate the shaft to its furthest clockwise position and then rotate counterclockwise two detents). Important: If the new PNP switch will not slide onto the selector shaft easily, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 7. Slide the new PNP switch over the selector shaft with the neutral assurance bracket 920 facing outward and maintaining the correct PNP switch orientation to the selector shaft. Install and hand tighten the two PNP switch attaching bolts so that the PNP switch and bracket may be rotated within the adjusting slots with some effort. 8. While holding the neutral assurance bracket in engagement with the PNP switch, tighten the two bolts that attach the PNP switch to the transmission case. Tighten Tighten the bolts to 27 N.m (20 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 6025 9. Remove and discard the neutral assurance bracket. Important: Installation of the front shield and rear shields are important. Without proper installation of the shield, a return repair is probable. Follow all directions as listed on the installation instructions sheet included in the Switch kit, P/N 29540479. 10. Fit the new shield onto the PNP switch so that it fits securely against the switch. Make sure this is done before reinstalling the shift lever. 11. Reinstall the shift lever. With a wrench keeping the shift lever from rotating, install the nut on the end of the selector shaft. Tighten. Tighten the nut to 24 N.m (18 lb ft). 12. Connect the wiring harness connectors to the PNP switch. 13. Attach the selector cable to the lever. Check and adjust if needed. 14. Go back to step 4 of the Diagnostics and insure the Tech 2 readings match the shift lever positions. Important: Clear all DTCs before returning the vehicle to the customer. 15. Return the vehicle to the customer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 6026 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 6027 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 6028 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 6031 Transmission Position Switch/Sensor: Adjustments Automatic Transmission - Allison Park/Neutral Position Switch Adjustment ^ Tools Required J 41364-A PNP Switch Adjusting Tool Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Make sure the selector shaft is in the N (Neutral) position as follows: ^ Place a wrench on the selector shaft flats and rotate the shaft to its furthest clockwise position. ^ Rotate the selector shaft counter-clockwise two detents. 2. Be sure that J 41364-A (2) is in the proper position on PNP switch (1). 3. While maintaining the correct PNP switch-to-selector-shaft alignment, slide the new PNP switch (5) over the selector shaft (4). 4. Notice: Refer to Component Fastener Tightening Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 6032 While holding J 41364-A in engagement with the PNP switch, install the two bolts (6) so that the PNP switch may be rotated with some effort. ^ Tighten the two bolts (6) to 27 Nm (20 ft. lbs.). 5. Remove J 41364-A. 6. Install splash shield (1), concave side toward PNP switch (3), over selector shaft (2). 7. Notice: Refer to Transmission Selector Shaft Abuse Notice in Service Precautions. Reinstall Shift Lever (2). Install nut (3), by hand, on the end of selector shaft (4). Use a wrench (1) to keep the shift lever from rotating. ^ Tighten nut (3) to 24 Nm (18 ft. lbs.) 8. Reconnect the shift selector linkage/cable to the shift lever (2). 9. Connect the external wiring harness to the PNP switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L80-E/4L85-E Park/Neutral Position Switch Replacement Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6035 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6036 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6037 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Park Lock Pawl and Actuator Replacement Park Lock Pawl and Actuator Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the park/neutral position (PNP) switch. 3. Remove the manual shaft nut and pin. 4. Remove the detent lever and actuator. 5. Remove the parking pawl bracket bolts. 6. Remove the parking pawl return spring. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6038 7. Use the modified screw extractor in order to remove the plug. 8. Remove the parking pawl shaft retainer, shaft and pawl. 9. Important: If the manual shaft binds in the case during removal, file or sand the shaft in the area adjacent to the detent lever. Remove the manual shaft. 10. Remove the manual shaft seal. Installation Procedure 1. Install the pawl shaft. 2. Install the parking pawl. 3. Install the plug using a 8 mm or (5/16 inch) rod with Loctite® or equivalent. 4. Install the retainer. 5. Install the pawl return spring. 6. Install the detent lever to the actuator. 7. Install the actuator over the parking pawl. 8. Install the manual shaft seal. 9. Lubricate the manual shaft with transmission oil and install the manual shaft into the case. 10. Install the nut on the shaft. 11. Install the roll pin. 12. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6039 Install the parking lock bracket bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 13. Install the PNP switch. 14. Install the transmission filter. 15. Fill the transmission to the proper level with Dexron® III transmission fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6040 Transmission Position Switch/Sensor: Service and Repair Automatic Transmission - Allison Park/Neutral Position Switch Replacement PNP Switch Removal Refer to Park/Neutral Position Switch Removal. PNP Switch Install Refer to Park/Neutral Position Switch Installation. 7. Notice: Refer to Transmission Selector Shaft Abuse Notice in Service Precautions. Reinstall shift lever (2). Install nut (3), by hand, on the end of selector shaft (4). Use a wrench (1) to keep the shift lever from rotating. ^ Tighten nut (3) to 24 Nm (18 ft. lbs.). 8. Reconnect the shift selector linkage/cable to the shift lever (2). 9. Connect the external wiring harness to the PNP switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Electrical Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Electrical Specifications > Page 6045 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 6046 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E Transmission Speed Sensor: Diagrams Automatic Transmission - 4L80-E/4L85-E Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 6049 Transmission Speed Sensor: Diagrams Automatic Transmission - Allison Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 6050 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E Transmission Speed Sensor: Service and Repair Automatic Transmission - 4L80-E/4L85-E Input Shaft Speed Sensor Replacement Input Shaft Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1). 5. Inspect the input speed sensor (1) for any evidence of damage. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6053 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the input speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector (1). 5. Lower the vehicle. Output Shaft Speed Sensor Replacement Output Shaft Speed Sensor Replacement Removal Procedure Important: This procedure is for 2-wheel drive (2WD) vehicles only. If the vehicle is equipped with 4-wheel drive (4WD), the output speed sensor is located on the transfer case. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6054 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2). 5. Inspect the output speed sensor (2) for any evidence of damage. Installation Procedure 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the output speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6055 4. Connect the output speed sensor (2) electrical connector. 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6056 Transmission Speed Sensor: Service and Repair Automatic Transmission - Allison Speed Sensor Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Be sure the vehicle ignition is turned off. 2. Disconnect the external wiring harness from the speed sensor. 3. Remove the bolt (1) from the speed sensor and carefully remove the speed sensor (2). Installation Procedure 1. Important: Do not rotate the sensor in its retaining bracket. Changing the sensor/bracket orientation may cause improper operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6057 Install a new a O-ring (3) on the speed sensor (2). Lubricate the O-ring with clean transmission fluid. 2. Install the new speed sensor (2) into the speed sensor bore. Align the hole in the retaining bracket with the bolt hole in the speed sensor boss. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor bolt (1). ^ Tighten bolt (1) to 12 Nm (108 inch lbs.). 4. Reconnect the external wiring harness to the speed sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Electrical Specifications Transmission Temperature Sensor/Switch: Electrical Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Electrical Specifications > Page 6062 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Electrical Specifications > Page 6063 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Component Locations Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Component Locations > Page 6066 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Instrument Panel Switches-LH Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 6071 Four Wheel Drive Selector Switch: Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 6072 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Transfer Case - NVG 246-NP8 Four Wheel Drive Selector Switch: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (I/P) cluster bezel. 2. Using a flat-tipped screwdriver, gently pry the retaining clips open on the housing. 3. Slide out the selector switch until the electrical connector are accessible. 4. Disconnect the selector switch electrical connectors (2, 3). 5. Remove the selector switch from the housing. Installation Procedure 1. Position the selector switch close to the housing so the electrical connectors can be connected. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Transfer Case - NVG 246-NP8 > Page 6075 2. Connect the selector switch electrical connectors (2, 3). 3. Slide the selector switch into the housing until the switch snaps into place. Important: Make sure that the selector switch is seated properly in the housing before installing the I/P cluster bezel. 4. Install the I/P cluster bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Transfer Case - NVG 246-NP8 > Page 6076 Four Wheel Drive Selector Switch: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (IP) cluster bezel. 2. Pull the tabs on the side of the transfer case driver control switch out. 3. Pull the transfer case driver control switch straight out from the panel. Installation Procedure 1. Important: Make sure that the transfer case control switch is seated properly in the instrument panel before installing the instrument panel trim bezel. Install the transfer case driver control switch into the instrument panel. 2. Install the IP cluster bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair Four Wheel Drive Selector Switch: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (IP) cluster bezel. 2. Pull the tabs on the side of the transfer case driver control switch out. 3. Pull the transfer case driver control switch straight out from the panel. Installation Procedure 1. Important: Make sure that the transfer case control switch is seated properly in the instrument panel before installing the instrument panel trim bezel. Install the transfer case driver control switch into the instrument panel. 2. Install the IP cluster bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: Customer Interest Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set > Page 6088 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: All Technical Service Bulletins Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set > Page 6094 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 06-04-21-001 > May > 06 > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 06-04-21-001 > May > 06 > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front > Page 6106 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 Speed Sensor: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 6109 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 6110 Speed Sensor: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Speed Sensor Replacement - Front Transfer Case Speed Sensor Replacement - Front Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the front speed sensor electrical connector (5). 3. Remove the front speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the front speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 6111 2. Connect the front speed sensor electrical connector (5). 3. Install the transfer case shield, if equipped. Transfer Case Speed Sensor Replacement - Left Rear Transfer Case Speed Sensor Replacement - Left Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the left rear speed sensor electrical connector (4). 3. Remove the left rear speed sensor. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 6112 1. Notice: Refer to Fastener Notice in Service Precautions. Install the left rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the left rear speed sensor electrical connector (4) 3. Lower the vehicle. Transfer Case Speed Sensor Replacement - Right Rear Transfer Case Speed Sensor Replacement - Right Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the right rear speed sensor electrical connector (3). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 6113 3. Remove the right rear speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the right rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the right rear speed sensor electrical connector (3). 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 6114 Speed Sensor: Service and Repair Transfer Case - NVG 261-NP2 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 6115 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 6116 Speed Sensor: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector. 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 6117 2. Connect the speed sensor electrical connector. 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 06535 > Aug > 06 > Campaign - ECM Software Upgrade PROM - Programmable Read Only Memory: Recalls Campaign - ECM Software Upgrade Bulletin No.: 06535 Date: August 09, 2006 SYSTEM SOFTWARE UPGRADE Subject: 06535-ON-BOARD DIAGNOSTIC (OBD) SYSTEM SOFTWARE UPGRADE - OBD SYSTEM IMPROVEMENTS (REPROGRAM POWERTRAIN CONTROL MODULE {PCM}) Models: 2004-05 CHEVROLET SILVERADO CHASSIS CAB, SUBURBAN, AVALANCHE 2004-05 GMC SIERRA CHASSIS CAB, YUKON XL EQUIPPED WITH DUAL FUEL TANKS Purpose This bulletin provides information about installing new Powertrain Control Module (PCM) software and calibration on certain involved 2004-05 Chevrolet Silverado chassis cab, Suburban, Avalanche; GMC Sierra chassis cab and Yukon XL model trucks, equipped with dual fuel tanks. The revised calibration includes OBD system improvements that affect the fuel level sender diagnostics that should be installed as soon as practical. Install the new calibration on all affected vehicles identified in this bulletin, including vehicles in new dealer inventory and any vehicles that return for service, for any reason, during the applicable 8 year / 80,000 mile (130,000 km) emission controller warranty coverage period. To verify if an updated calibration is required, refer to the following procedure in this bulletin. Parts Information Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into Control Modules via a Techline Tech 2 scan tool and the Techline Information System (TIS) 2000 terminal with the calibration update. Use data version 8.0 for 2006 or later, broadcast to dealers on August 6, 2006 or TIS 2 Web version 8.0 for 2006 (website version of TIS); and on TIS DVD version 8.0 / 2006 or later, mailed to dealers beginning August 23, 2006. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. Service Procedure The "Required Field Actions" section of the GM Vehicle Inquiry System (GMVIS) must be checked to determine if a specific vehicle requires this action. If GMVIS indicates that System Software Upgrade 06535 remains 'open' and PCM reprogramming has not taken place otherwise after the TIS Broadcast or DVD availability dates identified in this bulletin, reprogram the PCM using a Tech 2 scan tool with the calibration update from Techline Information System (TIS) 2000. Tech 2(R) Remote Programming Method for PCM Note: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic head lamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tool connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 06535 > Aug > 06 > Campaign - ECM Software Upgrade > Page 6126 are secure and the TIS terminal operating software is up to date. 1. Verify the battery charge of 12 to 16 volts. The battery must be able to maintain the charge during programming. Use an additional jump battery if necessary. 2. Use the normal "request method" through "Service Programming System" to request information from the vehicle. 3. At the Techline Terminal, enter TIS SPS programming system. 4. Select Tech 2(R) from the "Select Diagnostic Tool" window. 5. Select Reprogram ECU from the Select Programming Process window. 6. Select Vehicle from the "Select ECU Location" window. 7. Select Next to go to the "Preparing for Communication" instruction screen. 8. Select Next to view the Validate Vehicle ID Number screen. If the vehicle ID number does not appear on the screen, manually insert the VIN into the VIN window of the Validate Vehicle ID Number screen. 9. Select Next to view the "Supported Controllers" screen. 10. Select PCM/VCM Powertrain/Vehicle Control Module from "Supported Controllers" window. 11. Select Next to view the "Select Programming Type" window. 12. Select Normal from the Select Programming Type window. 13. Select Next to view the "Service Programming System Calibration Selection" screen. 14. Select Next to view Summary screen. 15. Verify that current and selected calibration information is displayed on the Summary screen. 16. Select Next to download the calibration to the Tech 2(R). 17. Back at the vehicle, enter "Service Programming Systems". 18. Select Program ECU and follow the on-screen instructions. 19. When programming is complete, do the following: 19.1. Turn the Tech 2(R) OFF. 19.2. Turn the ignition switch OFF. 20. Wait 30 seconds. 21. Turn the ignition switch to ON with the engine OFF. 22. Go into Diagnostics and check for DTC codes. 23. Clear all codes. Claim Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 06535 > Aug > 06 > Campaign - ECM Software Upgrade > Page 6127 For vehicles repaired under the 8 year/80,000 mile (130,000 km) emission controller warranty use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-027 > Apr > 06 > Engine Controls - SES Lamp ON/False DTC's P0116/P0181 PROM - Programmable Read Only Memory: Customer Interest Engine Controls - SES Lamp ON/False DTC's P0116/P0181 Bulletin No.: 06-06-04-027 Date: April 27, 2006 TECHNICAL Subject: LBZ, LB7, LLY, Service Engine Soon (SES) Light Illuminated, DTC P0116 or P0181 Set with Engine Coolant Heater Usage In Ambient Temperatures Above -18°C (0°F) (Replace Engine Coolant Heater Cord) Models: 2001-2006 Chevrolet Silverado 2006 Chevrolet Express Vans 2001-2006 GMC Sierra 2006 GMC Savana Vans with 6.6L Duramax(TM) Diesel V8 Engine (VINs D, 1, 2 - RPOs LBZ, LB7, LLY) Condition Some customers may comment on a Duramax(TM) Diesel vehicle with a Service Engine Soon (SES) light illuminated on the instrument cluster. Some vehicles may have been previously serviced for this same condition. Technicians may also find the following DTCs set with no concern found. ^ DTC P0116: Engine Coolant Temperature (ECT) Sensor Performance ^ DTC P0181: Fuel Temperature Sensor Performance Cause The Fuel Temperature Sensor, Engine Coolant Temperature (ECT), and Intake Air Temperature (IAT) sensors are compared to each other during a cold start to identify a concern with any one of the sensors. Engine coolant heater usage in ambient temperatures above -18°C (0°F) may trigger a false DTC P0116 or P0181. Correction The diesel supplement to the Owner's Manual advises that the engine coolant heater may be used below -1 8°C (0°F) to assist with cold starts. However, a customer may wish to plug in the heater when the overnight temperatures are unknown. A thermostatically controlled engine coolant heater cord is available for the prevention of false DTCs. This cord incorporates a thermostatic switch that only conducts below -18°C (0°F). Follow the steps below for the particular model year vehicle you are working on to ensure that the correct diagnostics are performed before replacing the engine coolant heater cord. 2001-2002 Vehicles 1. Verify that the updated calibration per Corporate Bulletin Number 02-06-04-058 has been installed. 2. Follow the published diagnostics in SI. 3. If no concern is found, determine if the customer is using the engine coolant heater above -18°C (0°F). 4. If the customer is using the engine coolant heater in ambient temperatures above -18°C (0°F), then replace the original coolant heater cord with the thermostatically controlled engine coolant heater cord, GM P/N 10369173. 2003-2006 Vehicles 1. Verify that the latest calibration has been installed. 2. Follow the published diagnostics in SI. 3. If no concern is found, determine if the customer is using the engine coolant heater above -18°C (0°F). 4. If the customer is using the engine coolant heater in ambient temperatures above -18°C (0°F), then replace the original coolant heater cord with the thermostatically controlled engine coolant heater cord, P/N 10369173. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-027 > Apr > 06 > Engine Controls - SES Lamp ON/False DTC's P0116/P0181 > Page 6133 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-01-007F > Mar > 10 > Diesel Engine Damage Due To Power-Up Devices PROM - Programmable Read Only Memory: All Technical Service Bulletins Diesel Engine Damage Due To Power-Up Devices INFORMATION Bulletin No.: 06-06-01-007F Date: March 31, 2010 Subject: Information On Identifying Duramax(TM) Diesel LB7, LLY, LMM, LBZ Overpower Engine Breakdown or Non-Function Due to Aftermarket Power-Up Devices vs. Non Overpower Engine Non-Function of Pistons, Cylinders, Valvetrain Components and/or Turbocharger DTC P003A Set Models: 2001-2010 Chevrolet Silverado 2003-2009 Chevrolet Kodiak 2006-2010 Chevrolet Express 2001-2010 GMC Sierra 2003-2009 GMC TopKick 2006-2010 GMC Savana Equipped With Duramax(TM) Turbocharged Diesel Engine RPOs LB7, LLY, LMM, LBZ Please Refer to GMVIS Supercede: This bulletin is being revised to add text to the end of the Caution statement. Please discard Corporate Bulletin Number 06-06-01-007E (Section 06 - Engine/Propulsion System). Caution Customers should be informed if a hard part failure is observed in the engine, transmission, transfer case and/or other driveline components, it is likely that powertrain components were weakened to the point of premature failure, while subjected to the higher stresses from Aftermarket Power-Up Devices. Failures associated with the installation of Aftermarket Power-Up Devices, which have been verified, are not covered under the terms of the New Vehicle Warranty. In the majority of these cases, the Fixed Operations Manager (FOM) (in Canada, Warranty Manager) should be contacted and the remaining portion of the powertrain portion of the New Vehicle Warranty blocked. GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage. General Motors Position On Aftermarket Power-Up Devices Important General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. Refer to Service Bulletin Number 04-06-04-054A or newer - Warranty Admin. - Non-GM Parts and Accessories (Aftermarket). Important For further information on aftermarket power-up kits, refer to February 2006 Emerging Issues Course Number 10206.02D. In Canada, information on aftermarket power-up kits was covered in the April 2006 TAC TALK program. Aftermarket power-up devices are non-approved by General Motors. These devices are usually piggy-backed in the main engine harness or remain connected to the diagnostic connector to upload the calibration to the ECM. Recent warranty reviews of returned engines show engine breakdown or non-function due to power-up devices that are utilized for increased horsepower and torque. The following information will assist technicians in identifying overpower engine breakdown or non-function due to aftermarket power-up devices vs. non overpower engine breakdown or non-function. Non-GM parts can alter the design of the vehicle. GM dealers need to be aware of the quality of parts being installed on vehicles. If failure occurs as a result of installation of sub-par parts, warranty coverage may be denied. Refer to Service Bulletin Number 04-06-04-054A or newer Warranty Admin. - Non-GM Parts and Accessories (Aftermarket). Installed Power-Up Kit Aftermarket power-up kits have become a very popular add on for performance-minded customers. These devices can add horsepower and torque and can add additional stress to the engine. These aftermarket calibrations take the Duramax(TM) powertrain outside of its design torque and horsepower rating. They do this by altering air/fuel ratios and injector timing, resulting in excessive cylinder pressure and temperature. When these calibrated parameters are altered, it will upset the design balance and can lead to a reduction of engine life expectancy. Generally, in inspection of Duramax(TM) engine failure due to power-up failures, two or more cylinders will be affected. Installed Power-Up Kit - Once installed, the calibration may mask itself with the factory original calibration ID and may remain the same. Refer to Service Bulletin Number 08-06-04-006F or newer - Information on Identifying Non-GM Calibration Usage for LMM Duramax(TM) Diesel Engine. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-01-007F > Mar > 10 > Diesel Engine Damage Due To Power-Up Devices > Page 6139 - A Tech 2(R) will not positively enable you to identify the use of a power-up device. - Some companies that offer power-up devices claim increases of 150 or more horsepower and 300 or more lb/ft pounds of torque. - A vehicle that is used to the power-up device potential 100% of the time will see earlier engine wear and breakdown. - A vehicle that takes advantage of additional power, but on a less frequent basis, may not see premature engine wear and breakdown until later in the engine's life. - A vehicle not pushed to its limits of the power-up device often may not encounter premature wear and breakdown until after the engine is out of warranty. Duramax(TM) Powertrain Horsepower / Torque Ratings The following horsepower and torque increase over the past years required new internal components to accommodate the increase. - LB7 - 300 hp with 520 ft/lb of torque for model years 2000-2004 - LLY - 310 hp with 605 ft/lb of torque for model years 2004-2008 - LBZ - 360 hp with 650 ft/lb of torque for model year 2006-2008 - LMM - 365 hp with 660 ft/lb of torque for model year 2007-2009 LBZ Improvements To reliably achieve an increase in 50 horsepower with 45 ft/lb torque, the Duramax (TM) diesel had to be revised in many areas. A few of the revisions on the 2006 LBZ were: - New pistons with a revised compression ratio. - Wrist pins that are larger in diameter. - Connecting rods with added material to increase the I section strength. - Engine block and machining changes - Cylinder heads Duramax(TM) Life Expectancy The Duramax(TM) 6.6L V8 Turbo Diesel Engine is sold with a warranty of 100,000 miles/160,000 kilometers. The Duramax(TM) has been tested to survive upwards of 200,000 miles/320,000 kilometers. The Duramax(TM) powertrain is designed for reliability, peak horsepower and torque within its design limits. When a customer installs a power-up device, it drastically reduces the mileage ratings. Important Cylinder Wall Spotting (commonly referred to leopard spots) is from the induction hardening process of the top 1/3 of the cylinder wall. This is normal for the Duramax (TM) Diesel. Identifying Fuel Related Aftermarket Power-Up Devices Aftermarket companies have developed a performance pressure relief fuel valve for Duramax(TM) diesel engines. Refer to above graphic illustration. The performance pressure relief fuel valve attaches to the fuel rail in place of the OEM valve and will not allow any fuel return to the tank, giving 100% of the fuel to be available for additional engine performance. This may cause additional fuel related driveability concerns and may set the following DTCs: - DTC P1093 Fuel Rail Pressure (FRP) Low During Power Enrichment - DTC P0087 Fuel Rail Pressure (FRP) Too Low Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-01-007F > Mar > 10 > Diesel Engine Damage Due To Power-Up Devices > Page 6140 Aftermarket companies have developed a replacement performance/economy fuel injector nozzle. Refer to above illustration. The performance/economy fuel injector nozzles replace the OEM fuel injector nozzles. The aftermarket companies claim increased horsepower, improved fuel atomization, lower exhaust gas temperatures and increase fuel economy. This may cause additional fuel related driveability concerns and may cause internal engine damage to the pistons and fuel injector nozzles. Identifying Overpower Engine Premature Wear and Breakdown When premature wear and breakdown is encountered due to an aftermarket power-up device, it has some very specific characteristics to the internal engine components. The following list will assist in identifying these characteristics as you tear down the engine. - Pistons will be cracked in the lip area, or a hole in the pistons. - Pistons can also be melted on the lip of the combustion bowl, or the top of the pistons can be melted. - Crosshatch will be polished off the cylinder wall in the major thrust face of cylinder below ring belt travel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-01-007F > Mar > 10 > Diesel Engine Damage Due To Power-Up Devices > Page 6141 - Piston pin bore will show signs of scoring, the wrist pins will be discolored, and can have oil coking on them. The connecting rod bushing surface will have accelerated wear. The above illustration shows a connecting rod bushing. - Oil coking on the underside of the piston between the wrist pin bosses. - Signs of bearing fretting will also be noticed on the connecting rod and main bearing caps. Refer to the above illustration for fretting of main bearing cap 1 and back side of connection rod bearing 2. - Excessive heat in engine compartment caused by overpower device. Refer to above illustration (1). Non Overpower Engine Premature Wear and Breakdown The following pictures show results of overheat, overspeed, low/no oil pressure or injector breakdown and how they differ from aftermarket power-up device premature wear and breakdown. Engine Overheat Overheat can be caused by a loss of coolant or a general cooling system failure. Some of the indicators of overheat are: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-01-007F > Mar > 10 > Diesel Engine Damage Due To Power-Up Devices > Page 6142 - Melted pistons. - Head gasket breakdown or non-function. - Warped cylinder heads. - Crankshaft and connecting rod discolored. Engine Overspeed Causes If an engine has been run faster than design capability (redline), and has caused damage as a result, it may be a result of one of the following conditions: - Leaking or failed turbocharger (TC) oil seals. - Oil evident in the intake runners and compressor side of the TC. - Starting fluid use or alternative fuel added to the engine such as ether. Engine Overspeed Results The following are indicators that an overspeed event took place: - Valve train damage. - Pushrods that are bent (4). - Broken valve bridge buttons after cylinder head removal (2). - Rocker arm tip damage (1). - Dry or rusted cylinders from the use of ether, propane or nitrous oxide. - Piston to valve contact. - Cam gear pin shear. Lack of Oil Pressure Lack of lubrication causes rapid bearing wear or bearing to seize. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-01-007F > Mar > 10 > Diesel Engine Damage Due To Power-Up Devices > Page 6143 Bearing failure. Spun main bearings. Engine Premature Wear and Breakdown Due to Improper Function of Fuel Injector A fuel injector may fracture a piston or melt a piston but the damage will be limited to that cylinder only and all other pistons and cylinder walls are OK. In some cases hydraulic lock will occur on the suspected cylinder with an over-fueling fuel injector. Hydraulic lock on the suspected cylinder will cause a bent connecting rod. This can be verified with piston protrusion measurements. 2007-2010 RPO LMM Only Turbocharger DTC P003A Set General Motors has identified a turbocharger (TC) failure mode involving Power-Up Kits that causes soot leakage and DTC P003A to be set. The Power-Up Kits create an overtemperature condition from the increased exhaust gas temperatures that results in a permanent and excessive turbine housing distortion at the TC case halves. 1. A technician may observe one or more of the following conditions: - DTC P003A being set as Current or in History. - An unusual odor emanating from the TC due to an overtemperature condition. - Soot leaking and accumulating at the V-band clamp that secures the TC case halves together. - Limited or unresponsive travel when Commanding the TC Vane Pos. Ctrl. Solenoid ON and OFF with a scan tool. 2. If DTC P003A is found as Current or in History, OR there is evidence of soot leakage (1) in the area of the V-band clamp (1), then technicians MUST verify if the engine control module (ECM) has a Power-Up Kit aftermarket calibration installed or an aftermarket hardware device has been installed. Refer to Service Bulletin Number 08-06-04-006F or newer for the calibration verification information and procedures. How to Handle a Suspect Engine Failure Due to a Power-Up Device Dealers should not automatically decline warranty assistance on engine failures due to the fact that a power-up device or modification is evident or suspected. The technician must identify that the failure is due to a power-up device by teardown analysis and diagnosis of the engine components. The following steps should be taken if an engine failure occurs and it is suspected that the modification or addition of a power-up device maybe the cause of the engine failure. If unclear of this process or direction feel free to contact your Fixed Operations Manager (in Canada, Warranty Manager) for further support. 1. The technician should use proper engine diagnostics to lead him/her to the failed engine components. The Aftermarket Power-Up Kit Check List should be followed and if it is determined that at least three of the Aftermarket Power-Up Kit Check List items match the engine component failures then it can be decided that the failure is not a warrantable claim. 2. Engine failures that meet at least three criteria of the Aftermarket Power-Up Kit Check List are considered failures that are not manufacturer's defects in workmanship or materials. 3. The dealership should contact the PQC, open a case to review the findings and make the final decision on warranty coverage. The Fixed Operations Manager (in Canada, Warranty Manager) should be notified of the PQC decision. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-01-007F > Mar > 10 > Diesel Engine Damage Due To Power-Up Devices > Page 6144 4. Denied claims should be documented as follows: 1. The Aftermarket Power-Up Kit Check List completed with the technicians detailed written findings of the diagnosis on the repair order and retained in the repair order file. 2. Photographs of the failed parts should be retained in the repair order file. 5. The customer should be advised that the failure of their engine was not due to a manufacturer's defect in workmanship or materials and therefore the warranty claim is denied on this failure. Aftermarket Power-Up Kit Check List Important Print and use this aftermarket power-up kit check list when performing an engine disassembly investigation of overpower engine breakdown or non-function. Retain a copy of this checklist and photographs of the failed parts in the repair order file. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06535 > Aug > 06 > Campaign - ECM Software Upgrade PROM - Programmable Read Only Memory: All Technical Service Bulletins Campaign - ECM Software Upgrade Bulletin No.: 06535 Date: August 09, 2006 SYSTEM SOFTWARE UPGRADE Subject: 06535-ON-BOARD DIAGNOSTIC (OBD) SYSTEM SOFTWARE UPGRADE - OBD SYSTEM IMPROVEMENTS (REPROGRAM POWERTRAIN CONTROL MODULE {PCM}) Models: 2004-05 CHEVROLET SILVERADO CHASSIS CAB, SUBURBAN, AVALANCHE 2004-05 GMC SIERRA CHASSIS CAB, YUKON XL EQUIPPED WITH DUAL FUEL TANKS Purpose This bulletin provides information about installing new Powertrain Control Module (PCM) software and calibration on certain involved 2004-05 Chevrolet Silverado chassis cab, Suburban, Avalanche; GMC Sierra chassis cab and Yukon XL model trucks, equipped with dual fuel tanks. The revised calibration includes OBD system improvements that affect the fuel level sender diagnostics that should be installed as soon as practical. Install the new calibration on all affected vehicles identified in this bulletin, including vehicles in new dealer inventory and any vehicles that return for service, for any reason, during the applicable 8 year / 80,000 mile (130,000 km) emission controller warranty coverage period. To verify if an updated calibration is required, refer to the following procedure in this bulletin. Parts Information Do not attempt to order the calibration number from GMSPO. The calibration numbers are programmed into Control Modules via a Techline Tech 2 scan tool and the Techline Information System (TIS) 2000 terminal with the calibration update. Use data version 8.0 for 2006 or later, broadcast to dealers on August 6, 2006 or TIS 2 Web version 8.0 for 2006 (website version of TIS); and on TIS DVD version 8.0 / 2006 or later, mailed to dealers beginning August 23, 2006. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. Service Procedure The "Required Field Actions" section of the GM Vehicle Inquiry System (GMVIS) must be checked to determine if a specific vehicle requires this action. If GMVIS indicates that System Software Upgrade 06535 remains 'open' and PCM reprogramming has not taken place otherwise after the TIS Broadcast or DVD availability dates identified in this bulletin, reprogram the PCM using a Tech 2 scan tool with the calibration update from Techline Information System (TIS) 2000. Tech 2(R) Remote Programming Method for PCM Note: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic head lamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tool connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06535 > Aug > 06 > Campaign - ECM Software Upgrade > Page 6149 are secure and the TIS terminal operating software is up to date. 1. Verify the battery charge of 12 to 16 volts. The battery must be able to maintain the charge during programming. Use an additional jump battery if necessary. 2. Use the normal "request method" through "Service Programming System" to request information from the vehicle. 3. At the Techline Terminal, enter TIS SPS programming system. 4. Select Tech 2(R) from the "Select Diagnostic Tool" window. 5. Select Reprogram ECU from the Select Programming Process window. 6. Select Vehicle from the "Select ECU Location" window. 7. Select Next to go to the "Preparing for Communication" instruction screen. 8. Select Next to view the Validate Vehicle ID Number screen. If the vehicle ID number does not appear on the screen, manually insert the VIN into the VIN window of the Validate Vehicle ID Number screen. 9. Select Next to view the "Supported Controllers" screen. 10. Select PCM/VCM Powertrain/Vehicle Control Module from "Supported Controllers" window. 11. Select Next to view the "Select Programming Type" window. 12. Select Normal from the Select Programming Type window. 13. Select Next to view the "Service Programming System Calibration Selection" screen. 14. Select Next to view Summary screen. 15. Verify that current and selected calibration information is displayed on the Summary screen. 16. Select Next to download the calibration to the Tech 2(R). 17. Back at the vehicle, enter "Service Programming Systems". 18. Select Program ECU and follow the on-screen instructions. 19. When programming is complete, do the following: 19.1. Turn the Tech 2(R) OFF. 19.2. Turn the ignition switch OFF. 20. Wait 30 seconds. 21. Turn the ignition switch to ON with the engine OFF. 22. Go into Diagnostics and check for DTC codes. 23. Clear all codes. Claim Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06535 > Aug > 06 > Campaign - ECM Software Upgrade > Page 6150 For vehicles repaired under the 8 year/80,000 mile (130,000 km) emission controller warranty use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-027 > Apr > 06 > Engine Controls SES Lamp ON/False DTC's P0116/P0181 PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - SES Lamp ON/False DTC's P0116/P0181 Bulletin No.: 06-06-04-027 Date: April 27, 2006 TECHNICAL Subject: LBZ, LB7, LLY, Service Engine Soon (SES) Light Illuminated, DTC P0116 or P0181 Set with Engine Coolant Heater Usage In Ambient Temperatures Above -18°C (0°F) (Replace Engine Coolant Heater Cord) Models: 2001-2006 Chevrolet Silverado 2006 Chevrolet Express Vans 2001-2006 GMC Sierra 2006 GMC Savana Vans with 6.6L Duramax(TM) Diesel V8 Engine (VINs D, 1, 2 - RPOs LBZ, LB7, LLY) Condition Some customers may comment on a Duramax(TM) Diesel vehicle with a Service Engine Soon (SES) light illuminated on the instrument cluster. Some vehicles may have been previously serviced for this same condition. Technicians may also find the following DTCs set with no concern found. ^ DTC P0116: Engine Coolant Temperature (ECT) Sensor Performance ^ DTC P0181: Fuel Temperature Sensor Performance Cause The Fuel Temperature Sensor, Engine Coolant Temperature (ECT), and Intake Air Temperature (IAT) sensors are compared to each other during a cold start to identify a concern with any one of the sensors. Engine coolant heater usage in ambient temperatures above -18°C (0°F) may trigger a false DTC P0116 or P0181. Correction The diesel supplement to the Owner's Manual advises that the engine coolant heater may be used below -1 8°C (0°F) to assist with cold starts. However, a customer may wish to plug in the heater when the overnight temperatures are unknown. A thermostatically controlled engine coolant heater cord is available for the prevention of false DTCs. This cord incorporates a thermostatic switch that only conducts below -18°C (0°F). Follow the steps below for the particular model year vehicle you are working on to ensure that the correct diagnostics are performed before replacing the engine coolant heater cord. 2001-2002 Vehicles 1. Verify that the updated calibration per Corporate Bulletin Number 02-06-04-058 has been installed. 2. Follow the published diagnostics in SI. 3. If no concern is found, determine if the customer is using the engine coolant heater above -18°C (0°F). 4. If the customer is using the engine coolant heater in ambient temperatures above -18°C (0°F), then replace the original coolant heater cord with the thermostatically controlled engine coolant heater cord, GM P/N 10369173. 2003-2006 Vehicles 1. Verify that the latest calibration has been installed. 2. Follow the published diagnostics in SI. 3. If no concern is found, determine if the customer is using the engine coolant heater above -18°C (0°F). 4. If the customer is using the engine coolant heater in ambient temperatures above -18°C (0°F), then replace the original coolant heater cord with the thermostatically controlled engine coolant heater cord, P/N 10369173. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-027 > Apr > 06 > Engine Controls SES Lamp ON/False DTC's P0116/P0181 > Page 6155 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-07-30-002E > Sep > 05 > Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Wiring Harness: All Technical Service Bulletins Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Bulletin No.: 01-07-30-002E Date: September 23, 2005 TECHNICAL Subject: Malfunction Indicator Lamp (MIL) On, Transmission Stuck in Second or Third Gear, Instrument Cluster Inoperative (Verify and Repair Source of Voltage Loss In Transmission Solenoid Power Supply Circuit) Models: 2006 and Prior GM Passenger Cars and Light Duty Trucks 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E, 4L65-E, 4L80-E or 4L85-E Automatic Transmission (RPOs M30, M32, M33, MT1, MN8) Supercede: This bulletin is being revised to update model years, add additional models and add additional diagnostic information. Please discard Corporate Bulletin Number 01-07-30-002D (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions: ^ The Malfunction Indicator Lamp (MIL) is ON. ^ The transmission is defaulted to second gear (4L80/85-E). ^ The transmission is defaulted to third gear (4L60/65-E). ^ The instrument cluster is inoperative. Upon investigation, one or all of the diagnostic trouble codes (DTCs) P0740, P0753, P0758, P0785, P0787, P0973, P0976, P1860, P2761, P2764 and P2769 may be set depending on the vehicle. Cause The most likely cause of this condition may be a loss of voltage to the transmission solenoid power supply circuit. This condition may also be the result of an incorrect installation of an aftermarket electronic device such as a remote starter or alarm system. Correction Important: If the vehicle is equipped with an aftermarket electronic device and the DTCs are being set when the device is being used, verify that the appropriate fuse is being supplied battery voltage during operation. If voltage is not present at this fuse, these DTCs will be set due to lack of voltage at the solenoids. This condition is most likely to occur with an incorrectly installed remote starting system. If this is the case, refer the customer to the installer of the system for corrections. ANY REPAIRS DUE TO AFTERMARKET INSTALLATION OF ACCESSORIES IS A NON-WARRANTABLE ITEM. 1. With the ignition switch in the RUN position, test for battery voltage at the circuit fuse in the transmission solenoid power supply circuit. Refer to the appropriate SI Document for the transmission solenoid power supply circuit information. 2. If battery voltage is present at the fuse, inspect the ignition voltage circuit between the fuse and the transmission for possible opens. 3. If battery voltage is not present at the fuse, test for continuity between the fuse and the ignition switch. If NO continuity is between the fuse and the ignition switch, repair the open in that circuit. 4. If you have continuity between the fuse and the ignition switch, the most likely cause is the ignition switch. Replace the ignition switch using the appropriate Ignition Switch Replacement procedure in SI. Refer to group number 2.188 of the parts catalog for part description and usage of the ignition switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-07-30-002E > Sep > 05 > Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's > Page 6161 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-07-30-002E > Sep > 05 > Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's > Page 6167 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 01-07-30-002E > Sep > 05 > Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's > Page 6173 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Component Locations Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Component Locations > Page 6181 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 6182 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement ^ Tools Required J 36850 Transjel Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission filter. 3. Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. Remove the reverse boost valve bushing retainer ring (2). 4. Remove the following from the reverse boost valve cylinder: ^ The reverse boost valve bushing ^ The reverse boost valve ^ The pressure regulator spring retainer ^ The pressure regulator spring ^ The pressure regulator valve ^ The reverse boost valve bushing Installation Procedure 1. Install the pressure regulator valve using J 36850. 2. Pre-assemble the following parts: ^ The reverse boost valve bushing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 6183 ^ A new reverse boost valve ^ A new pressure regulator spring retainer ^ The added isolator pressure regulator spring ^ The pressure regulator spring 3. Install the pre-assembled parts into the pump bore. 4. Install the reverse boost valve bushing retainer ring while holding the reverse boost valve bushing in place. Ensure the retainer ring (2) is in the groove. 5. Install the transmission filter. 6. Fill the transmission to the proper level with Dexron® III transmission fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 6187 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure 1. Caution: Refer to SIR Caution in Service Precautions. Disable the SIR system. 2. Remove the body control module (BCM). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 6188 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the BCM. 6. Enable the SIR system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Electrical Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Electrical Specifications > Page 6193 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 6194 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission 4L80-E/4L85-E Shift Solenoid: Diagrams Automatic Transmission - 4L80-E/4L85-E Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission 4L80-E/4L85-E > Page 6197 Shift Solenoid: Diagrams Automatic Transmission - Allison Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission 4L80-E/4L85-E > Page 6198 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission 4L80-E/4L85-E > Page 6199 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission 4L80-E/4L85-E > Page 6200 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission 4L80-E/4L85-E > Page 6201 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission 4L80-E/4L85-E > Page 6202 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6203 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. Remove the 1-2 accumulator, if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6204 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6205 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Notice: Refer to Fastener Notice in Service Precautions. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6206 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 6211 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 6212 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Remove the transmission filter. 2. Disconnect the transmission harness 20-way connector (1) from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. 3. Important: Removal of the valve body is not necessary for the following procedure. Remove the 1-2 accumulator. Do not remove the spacer plate. 4. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ Torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 5. Remove the TCC PWM solenoid retainer. 6. Remove the TCC PWM solenoid in order to access one of the TCC solenoid bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 6213 7. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 8. Remove the pressure control solenoid (377). 9. Remove the TCC solenoid bolts and the valve body bolts which retain the internal wiring harness. 10. Using J 28458 , release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the four tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 6214 12. Inspect the TCC solenoid and wiring harness for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid bolts. ^ Tighten the control valve body bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid bolts to 11 Nm (97 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 6215 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 6216 ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector (1) to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 6221 Transfer Case Actuator: Service and Repair Transfer Case Encoder Motor Replacement Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Disconnect the encoder motor electrical connector. 4. Remove the encoder motor bolts. 5. Remove the encoder motor. 6. Remove the actuator insulator gasket. 7. If replacing the encoder motor, remove the locating pins from the old motor. Installation Procedure Important: ^ If the encoder motor is being replaced because it is defective, ensure that the transfer case is in the neutral position. Manually shift the unit at the shift shaft. Use a crescent wrench, if necessary. ^ If the encoder motor is being replaced, a new gasket will come with the encoder motor. DO NOT reuse the old gasket. ^ A NEW encoder motor does NOT come with locating pins. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 6222 1. Install the locating pins to the NEW encoder motor. 2. Position a NEW actuator insulator gasket to the transfer case. 3. Install the encoder motor. Notice: Refer to Fastener Notice in Service Precautions. 4. Install encoder motor bolts. ^ Tighten the bolts, in the sequence shown, to 20 Nm (15 ft. lbs.). 5. Connect the encoder motor electrical connector. Ensure that the retention clips activate. 6. Install the front propeller shaft. 7. Install the transfer case shield, if equipped. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Component Locations Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Component Locations > Page 6229 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 6230 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement ^ Tools Required J 36850 Transjel Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission filter. 3. Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. Remove the reverse boost valve bushing retainer ring (2). 4. Remove the following from the reverse boost valve cylinder: ^ The reverse boost valve bushing ^ The reverse boost valve ^ The pressure regulator spring retainer ^ The pressure regulator spring ^ The pressure regulator valve ^ The reverse boost valve bushing Installation Procedure 1. Install the pressure regulator valve using J 36850. 2. Pre-assemble the following parts: ^ The reverse boost valve bushing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 6231 ^ A new reverse boost valve ^ A new pressure regulator spring retainer ^ The added isolator pressure regulator spring ^ The pressure regulator spring 3. Install the pre-assembled parts into the pump bore. 4. Install the reverse boost valve bushing retainer ring while holding the reverse boost valve bushing in place. Ensure the retainer ring (2) is in the groove. 5. Install the transmission filter. 6. Fill the transmission to the proper level with Dexron® III transmission fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 6235 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure 1. Caution: Refer to SIR Caution in Service Precautions. Disable the SIR system. 2. Remove the body control module (BCM). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 6236 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the BCM. 6. Enable the SIR system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Electrical Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Electrical Specifications > Page 6241 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 6242 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E Shift Solenoid: Diagrams Automatic Transmission - 4L80-E/4L85-E Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 6245 Shift Solenoid: Diagrams Automatic Transmission - Allison Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 6246 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 6247 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 6248 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 6249 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 6250 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6251 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. Remove the 1-2 accumulator, if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6252 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6253 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Notice: Refer to Fastener Notice in Service Precautions. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6254 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 6259 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 6260 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Remove the transmission filter. 2. Disconnect the transmission harness 20-way connector (1) from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. 3. Important: Removal of the valve body is not necessary for the following procedure. Remove the 1-2 accumulator. Do not remove the spacer plate. 4. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ Torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 5. Remove the TCC PWM solenoid retainer. 6. Remove the TCC PWM solenoid in order to access one of the TCC solenoid bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 6261 7. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 8. Remove the pressure control solenoid (377). 9. Remove the TCC solenoid bolts and the valve body bolts which retain the internal wiring harness. 10. Using J 28458 , release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the four tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 6262 12. Inspect the TCC solenoid and wiring harness for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid bolts. ^ Tighten the control valve body bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid bolts to 11 Nm (97 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 6263 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 6264 ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector (1) to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Accumulator: Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 6269 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 6270 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 6271 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Page 6272 Accumulator: Service and Repair Accumulator Housing Replacement ^ Tools Required J 25025-5 Valve Body Align Pin Removal Procedure 1. Remove the valve body. 2. Remove the 3rd and 4th clutch accumulator housing bolts (1). 3. Remove the 3rd and 4th clutch accumulator housing (8). 4. Remove the accumulator housing gasket (6). The accumulator housing gasket may be stuck to the spacer plate (5). 5. Remove the 3rd clutch accumulator piston spring (7). 6. Remove the 4th clutch accumulator piston spring (2). 7. Remove the valve body spacer plate (5). 8. Remove the valve body to spacer plate gasket (4) from the spacer plate (5). Third and Fourth Clutch Accumulator Disassembly 1. Important: Apply low pressure compressed air to the hole at the top of the accumulator housing to assist with the piston removal. Remove the 3rd clutch accumulator piston (2). 2. Remove the 3rd clutch accumulator piston seals (1, 3). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Page 6273 3. Remove the 4th clutch accumulator piston pin retainer ring (5). 4. Remove the 4th clutch accumulator piston (4) and pin (2) from the accumulator housing (1). 5. Remove the 4th clutch accumulator piston pin (2) from the accumulator housing (1). 6. Remove the 4th clutch accumulator piston seal (3) from the accumulator housing (1). Third and Fourth Clutch Accumulator Assembly 1. Install the 3rd clutch accumulator piston inner (3) and outer (1) seals. Lubricate the 3rd clutch accumulator piston seals (1, 3) with DEXRON® III automatic transmission fluid. 2. Install the 3rd clutch accumulator piston (2). 3. Install the 4th clutch accumulator piston seal (3). Lubricate the 4th clutch accumulator piston seal (3) with DEXRON® III automatic transmission fluid. 4. Assemble the 4th clutch accumulator piston pin (2) with the 4th clutch accumulator piston (4). 5. Install the 4th clutch accumulator piston assembly into the accumulator housing (1). 6. Install the 4th clutch accumulator piston pin retainer ring (5) onto the 4th clutch accumulator piston pin (2). Installation Procedure 1. Install J 25025 into the valve body bolt hole where the manual shaft detent roller and spring is mounted. 2. Install the valve body gasket (2) onto the accumulator housing (1). 3. Install the valve body spacer plate (3) onto the valve body gasket (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Page 6274 4. Install the third and fourth clutch accumulator housing gasket (3). 5. Install the third clutch accumulator piston spring (1). This spring is the longer of the two springs. 6. Install the fourth clutch accumulator piston spring (4). 7. Install the third and fourth clutch accumulator housing assembly (5) onto the control valve body assembly (2). 8. Install the six accumulator housing bolts (6). Start the bolts finger tight and work towards the opposite end. 9. Notice: Refer to Fastener Notice in Service Precautions. Tighten the accumulator housing bolts sequentially. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 10. Remove the J 25025. 11. Install the valve body. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: Customer Interest A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover > Page 6283 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-025A > Jul > 04 > A/T - 4L60-E/-4L65E No Shift/Slipping/Fluid Leaks Band Apply Servo: Customer Interest A/T - 4L60-E/-4L65E No Shift/Slipping/Fluid Leaks Bulletin No.: 04-07-30-025A Date: July 27, 2004 TECHNICAL Subject: Transmission Fluid Leak, Inoperative 2nd/3rd/4th Gears, No Movement, Case Cracked or Broken at 2-4 Servo (Repair Transmission and Install New Retaining Ring) Models: 2004 Chevrolet Corvette 2004 Pontiac GTO 2004 Light Duty Trucks with 4L60-E and 4L65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add the Corvette and GTO models and to include the 4L65-E transmission. Please discard Corporate Bulletin Number 04-07-30-025 (Section 07 Transmission/Transaxle). Condition Some customers may comment on a transmission leak, inoperative 2nd/4th gear, slipping 3rd/4th gear or no movement due to excess fluid loss. Cause This condition normally occurs at low mileage, usually under 1,600 km (1,000 mi), and investigation may show that the servo cover is loose or that the transmission case is cracked or broken at the servo bore. This condition may be caused by a servo cover retaining ring that did not retain the servo cover. The servo retaining ring design was changed for the 2004 MY from round wire to wire with two flat faces. In mid-April, 2004, the retaining ring design did revert back to a round design in production. It is possible that the transmission case may crack at the servo cover area due to the retaining ring being incorrectly seated. Correction Important: ^ In mid-April, 2004, the retaining ring design did revert back to a round design in production. ^ If the transmission fluid level has lowered due to loss of fluid, it is possible that damaged 3/4 clutches will result. ^ A cracked or broken case may usually be repaired at a significantly lower cost than transmission assembly replacement by replacing the case and any damaged clutches or bands. 1. Raise and suitably support the vehicle. 2. Inspect the transmission case around the servo cover for signs of cracks or damage to the case. ^ If the transmission case is cracked or damaged, replace the transmission case. Refer to the appropriate SI Document for Transmission Case Replacement. ^ If the servo cover is leaking and the case is not damaged, continue with the next step. 3. Remove the front exhaust pipe assembly. Refer to the appropriate SI Document. 4. Remove the heat shield if equipped. Refer to the appropriate SI Document. 5. Clean the servo cover area with Brake Clean and shop air. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-025A > Jul > 04 > A/T - 4L60-E/-4L65E No Shift/Slipping/Fluid Leaks > Page 6288 6. Install the J 29714-A. 7. Compress the servo cover with J 29714-A. Important: Flat-faced servo cover retaining rings that have been removed when servicing a transmission for any reason should not be re-used. 8. Remove the servo cover retaining ring. 9. Install the new round wire servo cover ring, P/N 24232065. 10. Remove J 29714-A. 11. Clean the servo cover area with Brake Clean and shop air. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. Refer to the appropriate SI Document. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-025A > Jul > 04 > A/T - 4L60-E/-4L65E No Shift/Slipping/Fluid Leaks > Page 6289 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: All Technical Service Bulletins A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover > Page 6295 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-025A > Jul > 04 > A/T - 4L60-E/-4L65E No Shift/Slipping/Fluid Leaks Band Apply Servo: All Technical Service Bulletins A/T - 4L60-E/-4L65E No Shift/Slipping/Fluid Leaks Bulletin No.: 04-07-30-025A Date: July 27, 2004 TECHNICAL Subject: Transmission Fluid Leak, Inoperative 2nd/3rd/4th Gears, No Movement, Case Cracked or Broken at 2-4 Servo (Repair Transmission and Install New Retaining Ring) Models: 2004 Chevrolet Corvette 2004 Pontiac GTO 2004 Light Duty Trucks with 4L60-E and 4L65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add the Corvette and GTO models and to include the 4L65-E transmission. Please discard Corporate Bulletin Number 04-07-30-025 (Section 07 Transmission/Transaxle). Condition Some customers may comment on a transmission leak, inoperative 2nd/4th gear, slipping 3rd/4th gear or no movement due to excess fluid loss. Cause This condition normally occurs at low mileage, usually under 1,600 km (1,000 mi), and investigation may show that the servo cover is loose or that the transmission case is cracked or broken at the servo bore. This condition may be caused by a servo cover retaining ring that did not retain the servo cover. The servo retaining ring design was changed for the 2004 MY from round wire to wire with two flat faces. In mid-April, 2004, the retaining ring design did revert back to a round design in production. It is possible that the transmission case may crack at the servo cover area due to the retaining ring being incorrectly seated. Correction Important: ^ In mid-April, 2004, the retaining ring design did revert back to a round design in production. ^ If the transmission fluid level has lowered due to loss of fluid, it is possible that damaged 3/4 clutches will result. ^ A cracked or broken case may usually be repaired at a significantly lower cost than transmission assembly replacement by replacing the case and any damaged clutches or bands. 1. Raise and suitably support the vehicle. 2. Inspect the transmission case around the servo cover for signs of cracks or damage to the case. ^ If the transmission case is cracked or damaged, replace the transmission case. Refer to the appropriate SI Document for Transmission Case Replacement. ^ If the servo cover is leaking and the case is not damaged, continue with the next step. 3. Remove the front exhaust pipe assembly. Refer to the appropriate SI Document. 4. Remove the heat shield if equipped. Refer to the appropriate SI Document. 5. Clean the servo cover area with Brake Clean and shop air. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-025A > Jul > 04 > A/T - 4L60-E/-4L65E No Shift/Slipping/Fluid Leaks > Page 6300 6. Install the J 29714-A. 7. Compress the servo cover with J 29714-A. Important: Flat-faced servo cover retaining rings that have been removed when servicing a transmission for any reason should not be re-used. 8. Remove the servo cover retaining ring. 9. Install the new round wire servo cover ring, P/N 24232065. 10. Remove J 29714-A. 11. Clean the servo cover area with Brake Clean and shop air. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. Refer to the appropriate SI Document. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-025A > Jul > 04 > A/T - 4L60-E/-4L65E No Shift/Slipping/Fluid Leaks > Page 6301 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Reverse Servo Replacement Band Apply Servo: Service and Repair Reverse Servo Replacement Reverse Servo Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the rear servo from the transmission case in the following order: 1. Cover bolts (6) 2. Cover (5) 3. Cover gasket (4) 4. Bottom retaining clip (3) 5. Servo piston (2) 6. Outer ring oil seal (1) 7. Inner ring oil seal (7) 8. Accumulator piston (8) 9. Piston seal (9) 10. Washer (10) 11. Servo spring (11) 12. Servo spring retainer (12) 13. Selective pin (13) 14. Accumulator spring (14) Installation Procedure 1. Install the rear servo to the transmission in the following order: 1. Accumulator spring (14) 2. Selective pin (13) 3. Servo spring retainer (12) 4. Servo spring (11) 5. Washer (10) 6. Piston seal (9) 7. Accumulator piston (8) 8. Inner ring oil seal (7) 9. Outer ring oil seal (1) 10. Servo piston (2) 11. Bottom retaining clip (3) 12. Cover gasket (4) 13. Cover (5) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Reverse Servo Replacement > Page 6304 14. Cover bolts (6) Notice: Refer to Fastener Notice in Service Precautions. 2. Tighten the cover bolts (61). ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 3. Install the transmission filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Reverse Servo Replacement > Page 6305 Band Apply Servo: Service and Repair Forward Servo Replacement Forward Servo Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the forward servo cover bolts, cover, and gasket. 3. Remove the following parts: 1. Forward servo piston pin (5) 2. O-ring seal (4) 3. Servo piston (3) 4. Retainer (2) 5. Piston spring (1) Installation Procedure 1. Install the following parts: ^ Piston spring (1) ^ Retainer (2) ^ Servo piston (3) ^ O-ring seal (4) ^ Forward servo piston pin (5) Notice: Refer to Fastener Notice in Service Precautions. 2. Install the forward servo gasket, cover, and bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 3. Install the transmission filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions Brake Switch - TCC: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6310 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6311 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6312 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6313 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6314 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6315 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6316 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6317 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6318 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6319 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6320 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6321 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6322 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6323 Brake Switch - TCC: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6324 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6325 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6326 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6327 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6328 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6329 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6330 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6331 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6332 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6333 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6334 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6335 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6336 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6337 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6338 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6339 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6340 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6341 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6342 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6343 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6344 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6345 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6346 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6347 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6348 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6349 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6350 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6351 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6352 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6353 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6354 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6355 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6356 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6357 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6358 Power, Ground and Brake Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 10-07-30-001C > Apr > 11 > A/T - Fluid/Oil Leak from Transmission Vent Case: Customer Interest A/T - Fluid/Oil Leak from Transmission Vent TECHNICAL Bulletin No.: 10-07-30-001C Date: April 13, 2011 Subject: Fluid/Oil Leak During Cold Weather from Transmission Vent (Early Models-Replace Transmission Fluid Level Indicator and Install New Transmission Vent Assembly) Models: 2001-2012 Chevrolet Silverado 2500HD-3500HD Series 2001-2012 GMC Sierra 2500HD-3500HD Series Equipped with Allison(R) LCT 1000 Automatic Transmission (RPOs M74, MW7) Supercede: This bulletin is being revised to add the 2012 model year and update information. Please discard Corporate Bulletin Number 10-07-30-001B (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a small red fluid/oil leak during cold weather. Upon further investigation, the technician may find a small fluid leak in the area at the back of the transmission by the vent. Cause This condition may be caused by fluid being discharged out the transmission vent due to a low transmission fluid fill. During extreme cold weather, (approximately -25°C (-15°F or colder), low fluid fill can cause the transmission pump to ingest air which can aerate the fluid and push some fluid out the vent. Correction On 2001 through 2012 models, verify the transmission is full of fluid. Follow the SI fluid checking procedure to PROPERLY check the transmission fluid level using the Hot Check Procedure. Important Ensure that the fluid level is at the top of the HOT band when the transmission fluid temperature is 79°C (175°F). Refer to SI Document ID# 2408059 for the proper fluid level checking procedure. Note Only on 2001-2004 models, replace the transmission fluid indicator (dipstick) with a new vented indicator, P/N 15794381. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 10-07-30-001C > Apr > 11 > A/T - Fluid/Oil Leak from Transmission Vent > Page 6367 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-025A > Jul > 04 > A/T 4L60-E/-4L65E No Shift/Slipping/Fluid Leaks Case: Customer Interest A/T - 4L60-E/-4L65E No Shift/Slipping/Fluid Leaks Bulletin No.: 04-07-30-025A Date: July 27, 2004 TECHNICAL Subject: Transmission Fluid Leak, Inoperative 2nd/3rd/4th Gears, No Movement, Case Cracked or Broken at 2-4 Servo (Repair Transmission and Install New Retaining Ring) Models: 2004 Chevrolet Corvette 2004 Pontiac GTO 2004 Light Duty Trucks with 4L60-E and 4L65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add the Corvette and GTO models and to include the 4L65-E transmission. Please discard Corporate Bulletin Number 04-07-30-025 (Section 07 Transmission/Transaxle). Condition Some customers may comment on a transmission leak, inoperative 2nd/4th gear, slipping 3rd/4th gear or no movement due to excess fluid loss. Cause This condition normally occurs at low mileage, usually under 1,600 km (1,000 mi), and investigation may show that the servo cover is loose or that the transmission case is cracked or broken at the servo bore. This condition may be caused by a servo cover retaining ring that did not retain the servo cover. The servo retaining ring design was changed for the 2004 MY from round wire to wire with two flat faces. In mid-April, 2004, the retaining ring design did revert back to a round design in production. It is possible that the transmission case may crack at the servo cover area due to the retaining ring being incorrectly seated. Correction Important: ^ In mid-April, 2004, the retaining ring design did revert back to a round design in production. ^ If the transmission fluid level has lowered due to loss of fluid, it is possible that damaged 3/4 clutches will result. ^ A cracked or broken case may usually be repaired at a significantly lower cost than transmission assembly replacement by replacing the case and any damaged clutches or bands. 1. Raise and suitably support the vehicle. 2. Inspect the transmission case around the servo cover for signs of cracks or damage to the case. ^ If the transmission case is cracked or damaged, replace the transmission case. Refer to the appropriate SI Document for Transmission Case Replacement. ^ If the servo cover is leaking and the case is not damaged, continue with the next step. 3. Remove the front exhaust pipe assembly. Refer to the appropriate SI Document. 4. Remove the heat shield if equipped. Refer to the appropriate SI Document. 5. Clean the servo cover area with Brake Clean and shop air. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-025A > Jul > 04 > A/T 4L60-E/-4L65E No Shift/Slipping/Fluid Leaks > Page 6372 6. Install the J 29714-A. 7. Compress the servo cover with J 29714-A. Important: Flat-faced servo cover retaining rings that have been removed when servicing a transmission for any reason should not be re-used. 8. Remove the servo cover retaining ring. 9. Install the new round wire servo cover ring, P/N 24232065. 10. Remove J 29714-A. 11. Clean the servo cover area with Brake Clean and shop air. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. Refer to the appropriate SI Document. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-025A > Jul > 04 > A/T 4L60-E/-4L65E No Shift/Slipping/Fluid Leaks > Page 6373 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-07-30-001C > Apr > 11 > A/T Fluid/Oil Leak from Transmission Vent Case: All Technical Service Bulletins A/T - Fluid/Oil Leak from Transmission Vent TECHNICAL Bulletin No.: 10-07-30-001C Date: April 13, 2011 Subject: Fluid/Oil Leak During Cold Weather from Transmission Vent (Early Models-Replace Transmission Fluid Level Indicator and Install New Transmission Vent Assembly) Models: 2001-2012 Chevrolet Silverado 2500HD-3500HD Series 2001-2012 GMC Sierra 2500HD-3500HD Series Equipped with Allison(R) LCT 1000 Automatic Transmission (RPOs M74, MW7) Supercede: This bulletin is being revised to add the 2012 model year and update information. Please discard Corporate Bulletin Number 10-07-30-001B (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a small red fluid/oil leak during cold weather. Upon further investigation, the technician may find a small fluid leak in the area at the back of the transmission by the vent. Cause This condition may be caused by fluid being discharged out the transmission vent due to a low transmission fluid fill. During extreme cold weather, (approximately -25°C (-15°F or colder), low fluid fill can cause the transmission pump to ingest air which can aerate the fluid and push some fluid out the vent. Correction On 2001 through 2012 models, verify the transmission is full of fluid. Follow the SI fluid checking procedure to PROPERLY check the transmission fluid level using the Hot Check Procedure. Important Ensure that the fluid level is at the top of the HOT band when the transmission fluid temperature is 79°C (175°F). Refer to SI Document ID# 2408059 for the proper fluid level checking procedure. Note Only on 2001-2004 models, replace the transmission fluid indicator (dipstick) with a new vented indicator, P/N 15794381. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-07-30-001C > Apr > 11 > A/T Fluid/Oil Leak from Transmission Vent > Page 6379 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-025A > Jul > 04 > A/T 4L60-E/-4L65E No Shift/Slipping/Fluid Leaks Case: All Technical Service Bulletins A/T - 4L60-E/-4L65E No Shift/Slipping/Fluid Leaks Bulletin No.: 04-07-30-025A Date: July 27, 2004 TECHNICAL Subject: Transmission Fluid Leak, Inoperative 2nd/3rd/4th Gears, No Movement, Case Cracked or Broken at 2-4 Servo (Repair Transmission and Install New Retaining Ring) Models: 2004 Chevrolet Corvette 2004 Pontiac GTO 2004 Light Duty Trucks with 4L60-E and 4L65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add the Corvette and GTO models and to include the 4L65-E transmission. Please discard Corporate Bulletin Number 04-07-30-025 (Section 07 Transmission/Transaxle). Condition Some customers may comment on a transmission leak, inoperative 2nd/4th gear, slipping 3rd/4th gear or no movement due to excess fluid loss. Cause This condition normally occurs at low mileage, usually under 1,600 km (1,000 mi), and investigation may show that the servo cover is loose or that the transmission case is cracked or broken at the servo bore. This condition may be caused by a servo cover retaining ring that did not retain the servo cover. The servo retaining ring design was changed for the 2004 MY from round wire to wire with two flat faces. In mid-April, 2004, the retaining ring design did revert back to a round design in production. It is possible that the transmission case may crack at the servo cover area due to the retaining ring being incorrectly seated. Correction Important: ^ In mid-April, 2004, the retaining ring design did revert back to a round design in production. ^ If the transmission fluid level has lowered due to loss of fluid, it is possible that damaged 3/4 clutches will result. ^ A cracked or broken case may usually be repaired at a significantly lower cost than transmission assembly replacement by replacing the case and any damaged clutches or bands. 1. Raise and suitably support the vehicle. 2. Inspect the transmission case around the servo cover for signs of cracks or damage to the case. ^ If the transmission case is cracked or damaged, replace the transmission case. Refer to the appropriate SI Document for Transmission Case Replacement. ^ If the servo cover is leaking and the case is not damaged, continue with the next step. 3. Remove the front exhaust pipe assembly. Refer to the appropriate SI Document. 4. Remove the heat shield if equipped. Refer to the appropriate SI Document. 5. Clean the servo cover area with Brake Clean and shop air. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-025A > Jul > 04 > A/T 4L60-E/-4L65E No Shift/Slipping/Fluid Leaks > Page 6384 6. Install the J 29714-A. 7. Compress the servo cover with J 29714-A. Important: Flat-faced servo cover retaining rings that have been removed when servicing a transmission for any reason should not be re-used. 8. Remove the servo cover retaining ring. 9. Install the new round wire servo cover ring, P/N 24232065. 10. Remove J 29714-A. 11. Clean the servo cover area with Brake Clean and shop air. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON(R)III transmission fluid. Refer to the appropriate SI Document. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-025A > Jul > 04 > A/T 4L60-E/-4L65E No Shift/Slipping/Fluid Leaks > Page 6385 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-023 > May > 04 > A/T 4L60-E/4L65-E New Pump/Seal/Case/Service Case: All Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-023 > May > 04 > A/T 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 6390 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-023 > May > 04 > A/T 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 6391 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-023 > May > 04 > A/T 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 6392 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-023 > May > 04 > A/T 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 6393 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 06-08-50-009F > Dec > 10 > Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set Seat Occupant Sensor: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC B0092 Set Bulletin No.: 02-09-41-002A Date: March 24, 2004 TECHNICAL Subject: Air Bag Lamp On, Passenger Air Bag Indicator Always Reads OFF, DTC B0092 Set (Repair Passenger Presence System (PPS) Sensor Harness) Models: 2003-2004 Cadillac Escalade, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon XL with Sensor Indicator Inflatable Restraint Front Passenger/Child Presence Detector (RPO ALO) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 02-09-41-002 (Section 09 - Restraints). Condition Some customers may comment that the Air Bag Lamp is on and the Passenger Air Bag indicator always reads OFF. Upon investigation, the technician may find DTC B0092 set. Cause The cause of this condition may be a shorted Passenger Presence System (PPS) sensor wire. The PPS sensor harness is located under the front passenger seat. This harness may be pinched between the seat frame and the track/riser. Correction Locate the PPS sensor (1) and inspect the harness for proper routing. If the harness is pinched between the seat frame and the track/riser, use the procedure listed below to repair wire(s). 1. Move the front passenger seat to the full rearward and full tilt up position. 2. Loosen the seat frame to track/riser nut and remove the harness. 3. Tighten the seat frame to track/riser nut. 4. Repair any damaged wires. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set > Page 6403 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set > Page 6413 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 6422 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 6432 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear Clutch: Customer Interest A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 6446 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 6447 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-027 > Jun > 08 > A/T No Movement in Drive or 3rd Gear Clutch: All Technical Service Bulletins A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-027 > Jun > 08 > A/T No Movement in Drive or 3rd Gear > Page 6457 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-027 > Jun > 08 > A/T No Movement in Drive or 3rd Gear > Page 6458 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-009B > May > 08 > A/T 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 06-08-50-009F > Dec > 10 > Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set Seat Occupant Sensor: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC B0092 Set Bulletin No.: 02-09-41-002A Date: March 24, 2004 TECHNICAL Subject: Air Bag Lamp On, Passenger Air Bag Indicator Always Reads OFF, DTC B0092 Set (Repair Passenger Presence System (PPS) Sensor Harness) Models: 2003-2004 Cadillac Escalade, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon XL with Sensor Indicator Inflatable Restraint Front Passenger/Child Presence Detector (RPO ALO) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 02-09-41-002 (Section 09 - Restraints). Condition Some customers may comment that the Air Bag Lamp is on and the Passenger Air Bag indicator always reads OFF. Upon investigation, the technician may find DTC B0092 set. Cause The cause of this condition may be a shorted Passenger Presence System (PPS) sensor wire. The PPS sensor harness is located under the front passenger seat. This harness may be pinched between the seat frame and the track/riser. Correction Locate the PPS sensor (1) and inspect the harness for proper routing. If the harness is pinched between the seat frame and the track/riser, use the procedure listed below to repair wire(s). 1. Move the front passenger seat to the full rearward and full tilt up position. 2. Loosen the seat frame to track/riser nut and remove the harness. 3. Tighten the seat frame to track/riser nut. 4. Repair any damaged wires. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set > Page 6472 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set > Page 6482 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair > Transmission Control Module Replacement Four Wheel Drive Selector Switch: Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair > Transmission Control Module Replacement > Page 6487 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair > Transmission Control Module Replacement > Page 6488 Four Wheel Drive Selector Switch: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (I/P) cluster bezel. 2. Using a flat-tipped screwdriver, gently pry the retaining clips open on the housing. 3. Slide out the selector switch until the electrical connector are accessible. 4. Disconnect the selector switch electrical connectors (2, 3). 5. Remove the selector switch from the housing. Installation Procedure 1. Position the selector switch close to the housing so the electrical connectors can be connected. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair > Transmission Control Module Replacement > Page 6489 2. Connect the selector switch electrical connectors (2, 3). 3. Slide the selector switch into the housing until the switch snaps into place. Important: Make sure that the selector switch is seated properly in the housing before installing the I/P cluster bezel. 4. Install the I/P cluster bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Technical Service Bulletins > Customer Interest for Automatic Transmission Dipstick - Dipstick Tube: > 10-07-30-001C > Apr > 11 > A/T - Fluid/Oil Leak from Transmission Vent Automatic Transmission Dipstick - Dipstick Tube: Customer Interest A/T - Fluid/Oil Leak from Transmission Vent TECHNICAL Bulletin No.: 10-07-30-001C Date: April 13, 2011 Subject: Fluid/Oil Leak During Cold Weather from Transmission Vent (Early Models-Replace Transmission Fluid Level Indicator and Install New Transmission Vent Assembly) Models: 2001-2012 Chevrolet Silverado 2500HD-3500HD Series 2001-2012 GMC Sierra 2500HD-3500HD Series Equipped with Allison(R) LCT 1000 Automatic Transmission (RPOs M74, MW7) Supercede: This bulletin is being revised to add the 2012 model year and update information. Please discard Corporate Bulletin Number 10-07-30-001B (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a small red fluid/oil leak during cold weather. Upon further investigation, the technician may find a small fluid leak in the area at the back of the transmission by the vent. Cause This condition may be caused by fluid being discharged out the transmission vent due to a low transmission fluid fill. During extreme cold weather, (approximately -25°C (-15°F or colder), low fluid fill can cause the transmission pump to ingest air which can aerate the fluid and push some fluid out the vent. Correction On 2001 through 2012 models, verify the transmission is full of fluid. Follow the SI fluid checking procedure to PROPERLY check the transmission fluid level using the Hot Check Procedure. Important Ensure that the fluid level is at the top of the HOT band when the transmission fluid temperature is 79°C (175°F). Refer to SI Document ID# 2408059 for the proper fluid level checking procedure. Note Only on 2001-2004 models, replace the transmission fluid indicator (dipstick) with a new vented indicator, P/N 15794381. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Technical Service Bulletins > Customer Interest for Automatic Transmission Dipstick - Dipstick Tube: > 10-07-30-001C > Apr > 11 > A/T - Fluid/Oil Leak from Transmission Vent > Page 6498 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Automatic Transmission Dipstick - Dipstick Tube: > 10-07-30-001C > Apr > 11 > A/T - Fluid/Oil Leak from Transmission Vent Automatic Transmission Dipstick - Dipstick Tube: All Technical Service Bulletins A/T - Fluid/Oil Leak from Transmission Vent TECHNICAL Bulletin No.: 10-07-30-001C Date: April 13, 2011 Subject: Fluid/Oil Leak During Cold Weather from Transmission Vent (Early Models-Replace Transmission Fluid Level Indicator and Install New Transmission Vent Assembly) Models: 2001-2012 Chevrolet Silverado 2500HD-3500HD Series 2001-2012 GMC Sierra 2500HD-3500HD Series Equipped with Allison(R) LCT 1000 Automatic Transmission (RPOs M74, MW7) Supercede: This bulletin is being revised to add the 2012 model year and update information. Please discard Corporate Bulletin Number 10-07-30-001B (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a small red fluid/oil leak during cold weather. Upon further investigation, the technician may find a small fluid leak in the area at the back of the transmission by the vent. Cause This condition may be caused by fluid being discharged out the transmission vent due to a low transmission fluid fill. During extreme cold weather, (approximately -25°C (-15°F or colder), low fluid fill can cause the transmission pump to ingest air which can aerate the fluid and push some fluid out the vent. Correction On 2001 through 2012 models, verify the transmission is full of fluid. Follow the SI fluid checking procedure to PROPERLY check the transmission fluid level using the Hot Check Procedure. Important Ensure that the fluid level is at the top of the HOT band when the transmission fluid temperature is 79°C (175°F). Refer to SI Document ID# 2408059 for the proper fluid level checking procedure. Note Only on 2001-2004 models, replace the transmission fluid indicator (dipstick) with a new vented indicator, P/N 15794381. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Automatic Transmission Dipstick - Dipstick Tube: > 10-07-30-001C > Apr > 11 > A/T - Fluid/Oil Leak from Transmission Vent > Page 6504 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair Extension Housing: Service and Repair Transmission Extension Housing Assembly Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Place a drain pan under the vehicle. 4. Remove the propeller shaft. 5. Remove the transmission support and the transmission mount. 6. Remove the case extension bolts (3). 7. Remove the case extension (1). 8. Remove and discard the case extension O ring seal (2). Installation Procedure 1. Install a new case extension O ring seal (2). 2. Install the case extension (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the case extension bolts (3). ^ Tighten the bolts (3) to 34 Nm (25 ft. lbs.). 4. Install the transmission support and the transmission mount. 5. Install the propeller shaft. 6. Remove the drain pan and the transmission jack. 7. Lower the vehicle. 8. Fill the transmission to the proper level with Dexron® III transmission fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine Runs Hot Towing or Pulling Grades Fluid - A/T: Customer Interest Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine Runs Hot Towing or Pulling Grades > Page 6516 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine Runs Hot Towing or Pulling Grades > Page 6517 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine Runs Hot Towing or Pulling Grades > Page 6518 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine Runs Hot Towing or Pulling Grades > Page 6519 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine Runs Hot Towing or Pulling Grades > Page 6520 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine Runs Hot Towing or Pulling Grades > Page 6521 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine Runs Hot Towing or Pulling Grades > Page 6522 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-037E > Apr > 11 > A/T DEXRON(R)-VI Fluid Information Fluid - A/T: All Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-037E > Apr > 11 > A/T DEXRON(R)-VI Fluid Information > Page 6528 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-035B > Nov > 10 > A/T Water Or Coolant Contamination Information Fluid - A/T: All Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-035B > Nov > 10 > A/T Water Or Coolant Contamination Information > Page 6533 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Fluid - A/T: All Technical Service Bulletins Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 6538 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 6539 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 6540 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 6541 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 6542 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 6543 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 6544 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-00-90-005 > May > 05 > A/T Allison, Service Interval/Filter Change Correction Fluid - A/T: All Technical Service Bulletins A/T - Allison, Service Interval/Filter Change Correction Bulletin No.: 05-00-90-005 Date: May 26, 2005 SERVICE MANUAL UPDATE Subject: Revised Maintenance and Lubrication for Automatic Transmission Service Interval/Correct Filter to Replace Models: 2001-2006 Chevrolet Silverado 2001-2006 GMC Sierra with Allison(R) Automatic Transmission This bulletin is being issued to revise the first automatic transmission service interval and specify what filter to replace in the Maintenance and Lubrication sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI for 2001-2004. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The 2005 and 2006 Owner's Manuals have also been corrected. The first automatic transmission service interval is at the first maintenance service performed on the vehicle. At that time, change the external spin-on filter only. At every 83,000 km (50,000 miles) (normal service) or every 41,500 km (25,000 miles) (severe service), change the external spin-on filter and fluid. The sump filter is to be changed only during an overhaul. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6554 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6555 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6556 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6561 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6562 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6563 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6564 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6565 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6566 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 09-06-04-034 > Aug > 09 > Fuel System - Reduced Engine Power, MIL (Various Codes) Wiring Harness: All Technical Service Bulletins Fuel System - Reduced Engine Power, MIL (Various Codes) TECHNICAL Bulletin No.: 09-06-04-034 Date: August 17, 2009 Subject: Malfunction Indicator Lamp (MIL) Illuminated, Fuel Injector Driver Circuit DTCs P0201, P0202, P0203, P0204, P0205, P0206, P0207, P0208 and Cylinder Bank Shut Down DTCs P2146 or P2149, Reduced Engine Power (Repair Fuel Injector Control Module (FICM) Harness Chafed Wires) Models: 2001-2004 Chevrolet Kodiak C4500/C5500 Series, Silverado Models 2001-2004 GMC Sierra Models, TopKick C4500/C5500 Series Equipped with Duramax(TM) Diesel Engine RPO LB7 2004-2005 Chevrolet Kodiak, Silverado Models 2004-2005 GMC Sierra Models, TopKick Equipped with Duramax Diesel Engine RPO LLY Please Refer to GMVIS Condition Some customers may comment that the malfunction indicator lamp (MIL) is illuminated or intermittent and there is a significant reduction in engine power (limp home mode). The scan tool may display one or more Injector Driver Circuit DTCs P0201, P0202, P0203, P0204, P0205, P0206, P0207 or P0208 and/or Cylinder Bank Shut Down DTCs P2146 or P2149 set as Current or in History. Cause This condition may be caused by the fuel injector control module (FICM) wiring harness protective conduit rubbing against the back of the alternator, the alternator bracket or the FICM harness retaining bracket. This may result in the conduit rubbing through, exposing the wires inside and chafing of the wire insulation then occurs. Correction 1. Turn ON the ignition, with the engine OFF. 2. Observe the DTC information with the scan tool. 3. If any of the above DTCs are set, then proceed to inspect the FICM wiring harness at the locations outlined in the following steps. 4. Turn OFF the ignition and all accessories and allow the control modules to power down. Note For Silverado and Sierra models only perform Step 5. 5. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. Important DO NOT break off the tab on the electrical connectors. 6. Disconnect the FICM electrical connectors (2) from the FICM (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 09-06-04-034 > Aug > 09 > Fuel System - Reduced Engine Power, MIL (Various Codes) > Page 6571 7. Carefully bend up and backwards the FICM wiring harness electrical connectors (1) away from the FICM (4). Note Some of these chafes are very small, possibly the size of a pen tip, but could still cause injector circuit concerns. 8. Inspect the wiring harness for chafing (3) that may result from rubbing at the back of the alternator (2), the alternator bracket or at the FICM harness retaining bracket. If necessary, peel the tape from the area and look for ANY chafes into the wires. ^ If chafing is observed and the conductive portion of the wire IS NOT damaged, apply electrical tape around the wire. ^ If chafing is observed and the conductive portion of the wire IS damaged, then refer to Splicing Copper Wire Using Splice Sleeves in Wiring Repairs in SI. ^ If chafing IS NOT OBSERVED, then refer to the appropriate DTC Diagnostic procedures in SI. 9. Connect the electrical connectors to the FICM. 10. Insulate the harness with suitable material such as conduit or heater hose to prevent a reoccurrence. Note For Silverado and Sierra models only perform Step 11. 11. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 12. Clear the DTCs with a scan tool. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 6576 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 03-08-50-014A > Jan > 06 > Electrical - No Module Communication/DTCs/Warning Lamps Wiring Harness: All Technical Service Bulletins Electrical - No Module Communication/DTCs/Warning Lamps Bulletin No.: 03-08-50-014A Date: January 20, 2006 TECHNICAL Subject: No Communication with Any Modules, Memory Seat May Not Recall, Multiple U-DTCs Set or Instrument Panel Cluster (IPC) Warning Indicators, Crank No Start (Inspect/Repair Affected Wiring Harness) Models: 2003-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL with Front, Individual (Non-Bkt) Seat (RPO AN3) and/or Active Brake Control (Stabilitrak(R)) (RPO JL4) Supercede: This bulletin is being revised to update the various conditions and add the 2004-2006 model years, additional diagnostic and warranty information. Please discard Corporate Bulletin Number 03-08-50-014 (Section 08 - Body & Accessories). Condition Some customers may comment on any of the following conditions: ^ Various IPC Warning indicators are coming on. ^ Driver Information Center (DIC) displays "Unknown Driver". ^ Memory seat may not recall. ^ RKE fobs may be inoperative. ^ Radio or HVAC may shut off. ^ Engine cranks but will not start. Upon investigation, the Technician may find multiple U-DTCs set. Cause On RPO AN3 equipped vehicles, a chafed or pinched seat wiring harness under the driver seat may be a cause of this condition. Because of the routing, a portion of the seat wiring harness may rest on the inboard edge of the seat track or frame. Over time, the harness may be pinched or chafed because of the seat movement. Refer to the above illustration. The illustration shows the inverted position of the seat bottom. The arrow shows the primary location Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 03-08-50-014A > Jan > 06 > Electrical - No Module Communication/DTCs/Warning Lamps > Page 6581 of the possible harness chafing/pinching. Also, on any of the above listed vehicles, the PCM wiring harness may be chafing against the precharge pump bracket or the battery tray. Correction On RPO AN3 vehicles, inspect the routing of the seat wiring harness. Reroute the seat wiring harness and attaching harness fastener (1) to the opposite side of the seat module bracket. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. The seat may have to be removed for ease of access and proper repair of the wiring harness. Inspect the routing of the PCM wiring harness at the precharge pump bracket and the battery tray. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. If any of the above conditions still remain after this repair, refer to SI for further diagnostic information. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6587 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6588 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6589 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6594 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6595 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6596 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6597 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6598 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6599 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 09-06-04-034 > Aug > 09 > Fuel System - Reduced Engine Power, MIL (Various Codes) > Page 6604 7. Carefully bend up and backwards the FICM wiring harness electrical connectors (1) away from the FICM (4). Note Some of these chafes are very small, possibly the size of a pen tip, but could still cause injector circuit concerns. 8. Inspect the wiring harness for chafing (3) that may result from rubbing at the back of the alternator (2), the alternator bracket or at the FICM harness retaining bracket. If necessary, peel the tape from the area and look for ANY chafes into the wires. ^ If chafing is observed and the conductive portion of the wire IS NOT damaged, apply electrical tape around the wire. ^ If chafing is observed and the conductive portion of the wire IS damaged, then refer to Splicing Copper Wire Using Splice Sleeves in Wiring Repairs in SI. ^ If chafing IS NOT OBSERVED, then refer to the appropriate DTC Diagnostic procedures in SI. 9. Connect the electrical connectors to the FICM. 10. Insulate the harness with suitable material such as conduit or heater hose to prevent a reoccurrence. Note For Silverado and Sierra models only perform Step 11. 11. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 12. Clear the DTCs with a scan tool. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 6609 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 03-08-50-014A > Jan > 06 > Electrical - No Module Communication/DTCs/Warning Lamps > Page 6614 of the possible harness chafing/pinching. Also, on any of the above listed vehicles, the PCM wiring harness may be chafing against the precharge pump bracket or the battery tray. Correction On RPO AN3 vehicles, inspect the routing of the seat wiring harness. Reroute the seat wiring harness and attaching harness fastener (1) to the opposite side of the seat module bracket. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. The seat may have to be removed for ease of access and proper repair of the wiring harness. Inspect the routing of the PCM wiring harness at the precharge pump bracket and the battery tray. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. If any of the above conditions still remain after this repair, refer to SI for further diagnostic information. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 4L60-E Pan Removal ........................................................................................... .......................................................................................................... 4.7L (5.0 Qt) Overhaul .............. .............................................................................................................................................................. ............................ 10.6L (11.0 Qt) 4L80-E Overhaul ........................................................................... ............................................................................................................................. 12.8L (13.5 Qt) Pan Removal .............................................................................................................................................. ....................................................... 7.3L (7.7 Qt) Allison Overhaul ..................................................... ................................................................................................................................................... 12.0L (12.7 Qt) Fluid and Filter Change ........................................................................................................ ............................................................................. 7.0L (7.4 Qt) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 6617 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 6618 Fluid - A/T: Service and Repair Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. Allow the transmission fluid to drain completely. 5. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the treads of the drain plug, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 7. Remove the drain pan from under the transmission oil pan. 8. Support the transmission with a transmission jack. 9. Remove the transmission mount nuts. 10. Remove the transmission support bolts and nuts. 11. Remove the transmission support side bracket bolts and bracket. 12. Remove the transmission support. 13. Disconnect the range selector cable end (2) from the transmission range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 6619 14. Important: It is not necessary to remove the selector cable from the bracket. Remove the transmission range selector cable bracket (2) bolts and bracket from the transmission. Reposition the bracket with cable. 15. Remove the oil pan bolts. 16. Important: The transmission oil pan gasket is reusable. Inspect the gasket and replace as needed. Remove the oil pan and gasket. 17. Remove the magnet from the bottom of the pan, if necessary. 18. Remove the oil filter. 19. Remove the filter neck seal. 20. Clean the transmission case and the oil pan gasket surfaces with solvent. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 6620 1. Install the filter neck seal. 2. Install the oil filter. 3. Install the oil pan gasket to the pan. 4. Install the magnet into the bottom of the pan, if necessary. 5. Install the oil pan and bolts. ^ Tighten the oil pan bolts to 24 Nm (18 ft. lbs.). 6. Position the bracket with cable. Install the transmission range selector cable bracket (2) and bolts to the transmission. ^ Tighten the selector bracket bolts to 25 Nm (18 ft. lbs.). 7. Connect the range selector cable end (2) to the transmission range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 6621 8. Install the transmission support. 9. Install the transmission support side bracket and bolts. 10. Install the transmission support bolts and nuts. ^ Tighten the bolts/nuts to 95 Nm (70 ft. lbs.). 11. Install the transmission mount nuts. ^ Tighten the nuts to 40 Nm (30 ft. lbs.). 12. Remove the transmission jack. 13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON® III transmission fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > A/T - Allison, Service Interval/Filter Change Correction Fluid Filter - A/T: Technical Service Bulletins A/T - Allison, Service Interval/Filter Change Correction Bulletin No.: 05-00-90-005 Date: May 26, 2005 SERVICE MANUAL UPDATE Subject: Revised Maintenance and Lubrication for Automatic Transmission Service Interval/Correct Filter to Replace Models: 2001-2006 Chevrolet Silverado 2001-2006 GMC Sierra with Allison(R) Automatic Transmission This bulletin is being issued to revise the first automatic transmission service interval and specify what filter to replace in the Maintenance and Lubrication sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI for 2001-2004. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The 2005 and 2006 Owner's Manuals have also been corrected. The first automatic transmission service interval is at the first maintenance service performed on the vehicle. At that time, change the external spin-on filter only. At every 83,000 km (50,000 miles) (normal service) or every 41,500 km (25,000 miles) (severe service), change the external spin-on filter and fluid. The sump filter is to be changed only during an overhaul. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Allison Fluid Filter - A/T: Service and Repair Allison Automatic Transmission Fluid/Filter Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Important: DO NOT drain the fluid if only the control main filter is being replaced. Remove drain plug (6) and drain plug seal (5). Drain the transmission fluid into a suitable container. 2. Inspect the drained fluid. 3. Important: Use a standard strap-type filter wrench to remove the control main filter. Remove filter (4) by rotating it in the counterclockwise direction. 4. Remove the magnet (2) from the filter attachment tube (1) in the converter housing or from the top of the control main filter (3). 5. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate that transmission replacement or overhaul is required. Installation Procedure 1. Reinstall the magnet (2) onto the filter attachment tube (1) which is in the converter housing. 2. Lubricate the gasket (3) on the control main filter with transmission fluid. 3. Install, by hand, the control main filter (4) until the gasket on the control main filter touches the converter housing. 4. Notice: Turning the control-main filter more than ONE FULL TURN after gasket contact will damage the filter and may cause fluid leakage. Turn the filter ONE FULL TURN ONLY after gasket contact. 5. Notice: Refer to Fastener Notice in Service Precautions. Reinstall the drain plug (6) and drain plug seal (5). ^ Tighten the drain plug to 35 Nm (26 ft. lbs.). 6. Refill Transmission with DEXRON®III Automatic Transmission Fluid. Refer to Fluid Capacity Specifications. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Allison > Page 6628 7. Important: DTC P0701 may often set following fluid service. Cycling the ignition clears the code and allows Drive or Reverse range to be attained. Cycle the ignition until Drive or Reverse range is attained. 8. Important: Fluid remains in the external circuits and transmission cavities after draining the transmission. Check the transmission fluid level. Control Main Filter Attachment Tube Control Main Filter Attachment Tube Replacement Removal Procedure Important: ^ DO NOT drain the fluid if only the control main filter attachment tube is being replaced. ^ Use a standard strap-type filter wrench to remove or install the control main filter. 1. Remove filter (4) by rotating it in the counterclockwise direction. 2. Remove the magnet (2) from the filter attachment tube (1) in the converter housing or from the filter element. 3. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate that transmission replacement or overhaul is required. 4. Remove the filter attachment tube (1) from the converter housing. Installation Procedure 1. Install the filter attachment tube (1). Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the attachment tube to 30 Nm (22 ft. lbs.). 2. Reinstall the magnet (2) onto the filter attachment tube (1). 3. Lubricate the gasket (3) on the control main filter with transmission fluid. 4. Install, by hand, the control main filter (4) until the gasket on the control main filter touches the converter housing. 5. Notice: Turning the control-main filter more than ONE FULL TURN after gasket contact will damage the filter and may cause fluid leakage. Turn the filter ONE FULL TURN ONLY after gasket contact. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Allison > Page 6629 6. Notice: Use only clean and approved transmission fluid. Check the transmission fluid level. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Allison > Page 6630 Fluid Filter - A/T: Service and Repair 4L80-E/4L85-E Automatic Transmission Fluid/Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. Allow the transmission fluid to drain completely. 5. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the treads of the drain plug, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 7. Remove the drain pan from under the transmission oil pan. 8. Support the transmission with a transmission jack. 9. Remove the transmission mount nuts. 10. Remove the transmission support bolts and nuts. 11. Remove the transmission support side bracket bolts and bracket. 12. Remove the transmission support. 13. Disconnect the range selector cable end (2) from the transmission range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Allison > Page 6631 14. Important: It is not necessary to remove the selector cable from the bracket. Remove the transmission range selector cable bracket (2) bolts and bracket from the transmission. Reposition the bracket with cable. 15. Remove the oil pan bolts. 16. Important: The transmission oil pan gasket is reusable. Inspect the gasket and replace as needed. Remove the oil pan and gasket. 17. Remove the magnet from the bottom of the pan, if necessary. 18. Remove the oil filter. 19. Remove the filter neck seal. 20. Clean the transmission case and the oil pan gasket surfaces with solvent. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Allison > Page 6632 1. Install the filter neck seal. 2. Install the oil filter. 3. Install the oil pan gasket to the pan. 4. Install the magnet into the bottom of the pan, if necessary. 5. Install the oil pan and bolts. ^ Tighten the oil pan bolts to 24 Nm (18 ft. lbs.). 6. Position the bracket with cable. Install the transmission range selector cable bracket (2) and bolts to the transmission. ^ Tighten the selector bracket bolts to 25 Nm (18 ft. lbs.). 7. Connect the range selector cable end (2) to the transmission range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Allison > Page 6633 8. Install the transmission support. 9. Install the transmission support side bracket and bolts. 10. Install the transmission support bolts and nuts. ^ Tighten the bolts/nuts to 95 Nm (70 ft. lbs.). 11. Install the transmission mount nuts. ^ Tighten the nuts to 40 Nm (30 ft. lbs.). 12. Remove the transmission jack. 13. Lower the vehicle. 14. Fill the transmission to the proper level with DEXRON® III transmission fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting Fluid Line/Hose: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 6638 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 6639 Fluid Line/Hose: Technical Service Bulletins A/T - Cooler Line Fitting Applications Bulletin No.: 08-07-30-004 Date: January 31, 2008 INFORMATION Subject: 4L60-E, 4L65-E, 4L70-E HYDRA-MATIC(R) Automatic Transmission (RPOs M30, M70 M32, M33, MK2 MD6) Oil Cooler Fitting Change Models: 1997-2008 GM Light Duty Trucks (Including Saab) with 4L60-E, 4L65-E, 4L70-E HYDRA-MATIC(R) Automatic Transmission (RPOs M30, M70, M3, M33, MK2, MD6) Aluminum cooler line fittings - These new fittings (2) cannot be used on earlier cases because the threaded hole is not the same size. Old style fittings (1) will continue to be available through SPO parts. Service cases will be the new case and fittings. The old cases with the old thread design will not be maintained for service. The connection on the hose side will accept both the short snout and the newer longer snout cooler hose assemblies. The fittings (1) have a new torque specification of 20 N.m (14 lb ft). They also have one inner and one outer "0" ring that are not serviced separately. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 6640 The new thread size 9/16-1a UNF-2A (1) was implemented on 11-29-07 or Julian date 333. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 6641 Fluid Line/Hose: Technical Service Bulletins A/T - Allison Cooler Line Adapter Tool/Flushing Bulletin No.: 05-07-30-002 Date: January 25, 2005 INFORMATION Subject: New Essential Tool J 45096-23 Automatic Transmission Oil Cooler Line Adapter for Allison Transmission Models: 2003-2005 Chevrolet Silverado 2003-2005 GMC Sierra with Allison Automatic Transmission (RPO M74) A revised transmission oil cooler line went into production during the 2003 model year. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 6642 A new transmission oil cooler line adapter tool , J 45096-23, is being released for use with the new oil cooler line. The outside diameter of the crimp on the end of the oil cooler line is slightly smaller than the previous transmission oil cooler line. Under certain conditions, the current tool, J 44835-1, could leak or come off if used on the improved design transmission oil cooler line. Refer to Corporate Bulletin Number 02-07-30-052C or newer for the proper transmission oil cooler flushing and flow test procedures. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Automatic Transmission - 4L60-E/4L65-E Fluid Line/Hose: Service and Repair Automatic Transmission - 4L60-E/4L65-E Transmission Fluid Cooler Hose/Pipe Replacement Removal Procedure 1. Remove the front grill assembly. 2. Remove the transmission fluid cooler hose from the Auxiliary oil cooler. 3. Remove the transmission fluid cooler hose from the radiator. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the engine protection shield. 6. Remove the cooling lines from the transmission. 7. Remove the oil cooling lines from the vehicle. Installation Procedure 1. Install the transmission oil cooler lines to the vehicle. 2. Install the cooling lines to the transmission. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Automatic Transmission - 4L60-E/4L65-E > Page 6645 3. Install the engine protection shield. 4. Lower the vehicle. 5. Install the transmission fluid cooler hose to the radiator. 6. Install the transmission fluid cooler hose to the Auxiliary oil cooler. 7. Install the front grill assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Automatic Transmission - 4L60-E/4L65-E > Page 6646 Fluid Line/Hose: Service and Repair Automatic Transmission - 4L80-E/4L85-E Transmission Fluid Cooler Hose/Pipe Replacement Removal Procedure 1. Remove the grille assembly. 2. Remove the transmission fluid cooler hose from the Auxiliary oil cooler. 3. Remove the transmission fluid cooler hose from the radiator. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the engine protection shield. 6. Remove the transmission fluid cooler hoses from the transmission. 7. Remove the transmission fluid cooler hoses from the retainer on the engine. 8. Remove the transmission fluid cooler hoses from the vehicle. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Automatic Transmission - 4L60-E/4L65-E > Page 6647 1. Install the transmission fluid cooler hoses to the vehicle. 2. Install the transmission fluid cooler hoses to the transmission. 3. Install the transmission fluid cooler hoses to the retainer on the engine. 4. Install the engine protection shield. 5. Lower the vehicle. 6. Install the transmission fluid cooler hose to the radiator. 7. Install the transmission fluid cooler hose from the Auxiliary oil cooler. 8. Install the grille assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Automatic Transmission - 4L60-E/4L65-E > Page 6648 Fluid Line/Hose: Service and Repair Automatic Transmission - Allison Transmission Fluid Cooler Hose/Pipe Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Pull the plastic cap back from the quick connect fitting. 3. Remove the cooling lines from the clips. 4. Remove the two retaining rings securing the two cooling lines to the transmission. 5. Use a bent tip screwdriver. 6. Pull on the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of the fitting. Discard the retaining ring. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Automatic Transmission - 4L60-E/4L65-E > Page 6649 7. Pull the cooling line straight out from the quick connect fitting. 8. Repeat this procedure to remove all the remaining cooling lines from quick connect fittings. 9. For vehicles without an auxiliary cooler, remove the cooling lines from the radiator. 10. For vehicles with auxiliary cooling, remove the cooling lines from the radiator. 11. Remove the oil cooling lines from the auxiliary oil cooler. Installation Procedure 1. Install the transmission oil cooler lines to the vehicle. 2. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Automatic Transmission - 4L60-E/4L65-E > Page 6650 ^ Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion. ^ Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. All retaining rings being installed must be new. ^ Ensure the following procedures are performed when installing the new retaining rings onto the fittings. Install a NEW retaining ring (E-clip) into the quick connect fitting using the following procedure: 3. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. 4. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. 5. Do not install the new retaining ring onto the fitting by pushing the retaining ring. 6. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. 7. Install the NEW retaining ring (E-clip) into the remaining quick connect fittings. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Automatic Transmission - 4L60-E/4L65-E > Page 6651 8. Install the cooler line into the quick connect fitting. 9. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. 10. Install the cooler lines to the vehicle. 11. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 12. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. 13. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. 14. Ensure that the plastic cap is fully seated against the fitting. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Automatic Transmission - 4L60-E/4L65-E > Page 6652 15. Ensure that no gap is present between the cap and the fitting. 16. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. A hidden yellow identification band indicates proper joint seating. 17. Do not install the cooler line end into the fitting incorrectly. 18. If you cannot position the plastic cap against the fitting, remove the retaining ring from the quick connect fitting. Check the retaining ring and the tube end in order to ensure neither is bent. Replace the cooler line or the retaining ring if necessary, and reinstall the cooler line per the installation procedure. 19. For vehicles without auxiliary cooling, install the cooling lines to the radiator. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Automatic Transmission - 4L60-E/4L65-E > Page 6653 20. For vehicles with auxiliary cooling, install the cooling lines to the radiator. 21. For vehicles with auxiliary cooling, install the oil cooling lines to the auxiliary oil cooler. 22. Install the cooling lines to the transmission. 23. Install the cooling lines to the clips. 24. Ensure all of the protective plastic caps are positioned over all of the quick connect fittings. 25. Lower the vehicle. 26. Check and add fluid as necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Pan Magnet Upgrade Fluid Pan: Technical Service Bulletins A/T - Fluid Pan Magnet Upgrade INFORMATION Bulletin No.: 08-07-30-040B Date: May 05, 2009 Subject: Information on Normal Maintenance or Warranty Service for 4T40, 4T45, 4T65, 4L60 Automatic Transmission Oil Pan Magnet Upgrade Models: 2002-2009 GM Passenger Cars and Light Duty Trucks Equipped With the Following Transmissions: 4T40-E or 4T45 HYDRA-MATIC(R) Automatic Transmission (RPOs MN4, MN5, ME7) 4T65 Transmission (RPO M15 and MN7) 4L60 Transmission and Derivatives (RPO M30 is 4L60, M32 is 4L65, M70 is 4L70) Attention: Do not remove the transmission oil pan unless normal maintenance or diagnosis of a customer concern requires it. .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add 4T65 and 4L60 transmissions. Please discard Corporate Bulletin Number 08-07-30-040A (Section 07 - Transmission/Transaxle). .............................................................................................................................................................. .................................................................................. A new transmission oil pan magnet, P/N 29535617, was released for service. The current square transmission oil pan magnet may become saturated with normal ferrous sediment and the Pressure Control Solenoid (PCS) is now collecting ferrous sediment, making it vary from design. For a given current the PCS electromagnet is stronger, causing the line pressure to be less than needed. When checking PCS line pressure (refer to Line Pressure Check in SI) and it shows that the line pressure is lower than required (refer to Current-Amps/Line Pressure Chart in SI), for a given current at the PCS or the transmission oil pan was removed (for either normal maintenance or warranty service), only then should the transmission oil pan magnet be upgraded. 1. Remove and discard the original square transmission oil pan magnet and install a new one in the current location (See graphics below for the correct application). 2. Install the second new transmission oil pan magnet in the following location as shown in the illustration. 4T40 & 4T45 4T65E Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Pan Magnet Upgrade > Page 6658 Note Only on 4T65E, the second magnet (left) should be attached to the transmission filter. If the magnet is attached in any other location, it may cause interference (refer to graphic above). 4L60 Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Pan Magnet Upgrade > Page 6659 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Automatic Transmission - 4L80-E/4L85-E Fluid Pan: Specifications Automatic Transmission - 4L80-E/4L85-E oil pan bolts ......................................................................................................................................... ..................................................... 24 Nm (18 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Automatic Transmission - 4L80-E/4L85-E > Page 6662 Fluid Pan: Specifications Automatic Transmission - Allison Oil Pan Bolts ........................................................................................................................................ .................................................... 27 Nm (20 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 6663 Fluid Pan: Service and Repair Oil Pan Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Important: It would be helpful to record the amount of transmission fluid lost during this procedure. Fluid in good condition, drained into a clean container, may be reused. Remove drain plug (7) and drain plug seal (6) from oil pan (5). Allow the fluid to drain into a suitable container. 3. Inspect the drained fluid. 4. Remove 12 bolts (8). Hold the oil pan in position as the last bolt is removed. 5. Remove oil pan (5) and gasket (3). 6. Inspect magnet (4). Excessive metallic particles or large metallic particles may indicate need for overhaul or replacement of the transmission. 7. Important: DO NOT remove the suction filter or seal if only replacing the oil pan or oil pan gasket. Remove suction filter (2) by pulling straight down where the suction tube is seated in the main housing. 8. Remove suction seal (1) from the filter or from the seal bore in the main housing. Discard the old seal. Discard the filter, if it is being replaced. Installation Procedure 1. Remove all gasket material from the main housing. Remove any scratches from the main housing that would cause a splitline leak. 2. Place a new seal (1) on the tube of suction filter (2), if it was removed. Be sure the seal locates against the shoulder on the suction filter tube. 3. Push the filter (2) and seal (1) into the seal bore in the main housing. Position the suction filter properly. 4. Install two headless guide bolts (9) (M8 x 1.25) into opposite corners of the oil pan mounting face on the main housing. 5. Place a gasket (3) on the oil pan and align the bolt holes. 6. Slide the gasket (3) and oil pan (5) over the guide bolts and hold them in place while installing two bolts (8) to hold the parts in place. 7. Notice: Refer to Fastener Notice in Service Precautions. Install the remainder of the 12 bolts (8) (two will replace the guide bolts). ^ Tighten the bolts to 27 Nm (20 ft. lbs.). 8. Notice: Refer to Component Fastener Tightening Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 6664 Reinstall drain plug (7) and drain plug seal (6). ^ Tighten the drain plug to 35 Nm (26 ft. lbs.). 9. Lower the vehicle. 10. Notice: Use only clean and approved transmission fluid. Refill the transmission with DEXRON® III Automatic Transmission Fluid. Refer to Fluid Capacity Specifications. 11. Important: Remember fluid remains in the external circuits and transmission cavities after draining the transmission. Check the transmission fluid level. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Component Locations Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Component Locations > Page 6669 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 6670 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 6671 Fluid Pressure Sensor/Switch: Service and Repair Pressure Switch Manifold Replacement Removal Procedure 1. Important: Individual pressure switches cannot be replaced. When any pressure switch needs replacing, the entire assembly must be replaced. Important: The G solenoid has been removed for clarity. Remove the oil pan and suction filter. 2. Remove the two bolts (2). Remove the reverse signal tube (1). 3. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the internal wiring harness connector from the pressure switch assembly (2). 4. Remove five bolts (1). Remove the pressure switch assembly (2). Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 6672 1. Notice: Refer to Fastener Notice in Service Precautions. Place the new pressure switch manifold assembly (2) in position and install one bolt (1) in a recessed location to hold it into position. Start the remaining four bolts (1) in recessed locations and tighten the bolts by hand. Torque the bolts to 12 Nm (108 inch lbs.). 2. Connect the internal wiring harness connector to the pressure switch assembly. 3. Install the reverse signal tube (1). Install two bolts (2). ^ Tighten the bolts to 12 Nm (108 inch lbs.). 4. Install the oil pan and suction filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Fluid Pump: Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 6677 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 6678 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 6679 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 6680 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 6681 Fluid Pump: Technical Service Bulletins A/T - 4L65E, 4L60E, 4L60, 200-4R Oil Pump Spring Bulletin No.: 04-07-30-006 Date: February 11, 2004 INFORMATION Subject: 4L65-E, 4L60-E, 4L60 and 200-4R Automatic Transmission Oil Pump Spring First and Second Design Identification Models: 2004 and Prior Passenger Cars and Light Duty Trucks 2003-2004 HUMMER H2 with 4L65-E, 4L60-E, 4L60 or 200-4R Automatic Transmission The purpose of this bulletin is to identify the oil pump spring usage for the two different pump designs. Manufacturing of the first design oil pump springs ended December 15, 2003. Manufacturing of the second design oil pump spring began December 16, 2003 The first design oil pump springs (206) and (207) DO NOT have any identification markings. The first design springs (206) and (207) use an inner and outer spring, two springs. The second design oil pump spring (245) is identified with tapered ends on the spring (245) as shown above. The second design spring (245) is a single spring. When servicing either (first design or second design) oil pump body, use the new single oil pump spring (245) with tapered ends. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 6682 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 6683 Fluid Pump: Technical Service Bulletins A/T - 4L60-E Oil Pump Identification Bulletin No.: 03-07-30-056 Date: November 05, 2003 INFORMATION Subject: 4L60-E Automatic Transmission Oil Pump First And Second Design Identification Models: 1997-2002 Chevrolet Camaro 1997-2002 Pontiac Firebird 2002-2004 Cadillac Escalade, Escalade EXT 1997-1999 Chevrolet C/K Full Size Pickup 1997-2004 Chevrolet Astro, Blazer, Corvette, Express, S-10, Suburban 1999-2004 Chevrolet Silverado 2000-2004 Chevrolet Tahoe 2002-2004 Chevrolet Avalanche, TrailBlazer 2004 Chevrolet Colorado, SSR 1997-1999 GMC Suburban 1997-2001 GMC Jimmy 1997-2004 GMC Envoy, Safari, Savana, Sierra, Sonoma 1999-2004 GMC Denali 2000-2004 GMC Yukon, Yukon XL 2004 GMC Canyon 1997-2004 Oldsmobile Bravada 2003-2004 HUMMER H2 with 4L60-E Automatic Transmission (RPOs M30, M32, M33) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 6684 The purpose of this bulletin is to identify the correct oil pump rotor (212) and slide (203) usage for the two different transmission oil pump designs. Manufacturing of the first design oil pump rotor (212) and slide (203) ended November 30, 2000. Manufacturing of the second design oil pump rotor (212) and slide (203) began December 1, 2000. Important: It is critical that the first and second design oil pump rotors and slides do not become intermixed. Do not use first design pump components with second design pump components. If the pump components from either design are intermixed, pump efficiency will be affected resulting in less than optimal pump performance. The first design oil pump rotor (212) and slide (203) DO NOT have any identification markings. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 6685 The second design oil pump rotor (212) and slide (203) are identified with dimples (circular depression) as shown above. The rotor (212) has two dimples adjacent to the rotor drive tangs (1). The slide (203) has one dimple located on the spring tab (2). Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Maintenance Indicator - A/T > Component Information > Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation PRNDL DISPLAY The IPC displays the selected gear position as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the gear position. The PRNDL display blanks if: - The IPC receives a class 2 message indicating the park position and the column park switch indicates a position other than park, open input. - The IPC detects a loss of class 2 communications with the PCM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Maintenance Indicator A/T > Component Information > Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise Output Shaft: Technical Service Bulletins A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise INFORMATION Bulletin No.: 01-07-30-042F Date: February 05, 2010 Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X with 4L60-E, 4L65-E or 4L70-E Automatic Transmission (RPOs M30, M32, M70) Supercede: This bulletin is being revised to add the 2010 model year and 4L70E transmission. Please discard Corporate Bulletin Number 01-07-30-042E (Section 07 - Transmission/Transaxle). Important For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin 05-07-30-012. Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift. During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band applied. This condition may be worse on a 4-wheel drive vehicle due to the additional tolerances in the transfer case. This is a normal condition. No repairs should be attempted. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Yoke, A/T > Component Information > Service and Repair Output Yoke: Service and Repair Output Flange/Yoke Replacement Removal Procedure 1. Place the transmission in the P (Park) selector position. 2. Caution: Apply the parking brake and block the drive wheels before performing this procedure in order to prevent bodily injury. Apply the parking brake and chock the wheels to prevent vehicle movement. 3. Remove the vehicle driveline from the transmission yoke assembly. 4. Remove the bolt (3) and seal ring washer (2). Remove the yoke assembly (1). 5. Important: Do the following prior to installation of the yoke assembly: ^ Be sure the yoke, output shaft and retaining hardware are clean. ^ Verify the output seal is free of tears or cuts. ^ DO NOT attempt to remove scratches from the output seal journal on the yoke assembly. Repair may produce machine lead and leakage. Inspect the yoke assembly and replace it whenever there are nicks or scratches on the seal journal or on the lead-in chamfer just ahead of the seal journal. Installation Procedure 1. Lubricate the internal splines and the rear seal journal of the yoke assembly with clean transmission fluid. 2. Install the yoke assembly (1) onto the transmission output shaft. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the bolt (3) and seal ring washer (2). ^ Tighten the bolt to 123 Nm (91 ft. lbs.). 4. Attach the vehicle driveline to the transmission yoke assembly. 5. Be sure the selector is in the P (Park) position. 6. Remove the wheel chocks before continuing operation of the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Component Locations Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Component Locations > Page 6707 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 6708 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement ^ Tools Required J 36850 Transjel Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission filter. 3. Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. Remove the reverse boost valve bushing retainer ring (2). 4. Remove the following from the reverse boost valve cylinder: ^ The reverse boost valve bushing ^ The reverse boost valve ^ The pressure regulator spring retainer ^ The pressure regulator spring ^ The pressure regulator valve ^ The reverse boost valve bushing Installation Procedure 1. Install the pressure regulator valve using J 36850. 2. Pre-assemble the following parts: ^ The reverse boost valve bushing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 6709 ^ A new reverse boost valve ^ A new pressure regulator spring retainer ^ The added isolator pressure regulator spring ^ The pressure regulator spring 3. Install the pre-assembled parts into the pump bore. 4. Install the reverse boost valve bushing retainer ring while holding the reverse boost valve bushing in place. Ensure the retainer ring (2) is in the groove. 5. Install the transmission filter. 6. Fill the transmission to the proper level with Dexron® III transmission fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Service and Repair > Transmission Control Module Replacement Control Module: Service and Repair Transmission Control Module Replacement Transmission Control Module (TCM) Replacement Removal Procedure Important: ^ Remove any debris from the transmission control module(TCM) connector surfaces before servicing the TCM. Inspect the TCM module connector gaskets when diagnosing or replacing the TCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the TCM. ^ The ignition must be OFF when disconnecting or reconnecting power to the TCM. 1. Disconnect the negative battery cable. 2. Remove the TCM cover bolts (1) located on the left side of the radiator shroud. 3. Pull the cover and TCM up and away from the radiator shroud. 4. Push up on the retainers (1) in order to remove the TCM from the cover. 5. Disconnect the TCM electrical connectors (2) and remove the TCM from the vehicle. Installation Procedure 1. Connect the TCM electrical connectors (2) to the TCM. 2. Install the TCM to the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Service and Repair > Transmission Control Module Replacement > Page 6715 3. Using the alignment tabs (1), install the cover and module to the radiator shroud. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the TCM cover bolts (1) to the radiator shroud. ^ Tighten the bolts to 9 Nm (80 inch lbs.). 5. Connect the negative battery cable. 6. Reprogram the TCM. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Service and Repair > Transmission Control Module Replacement > Page 6716 Control Module: Service and Repair Transmission Control Module Reprogramming Procedures Transmission Control Module Reprogramming Procedures Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install new module before proceeding. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the Electronic Control Unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to Program/Reprogram. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Reconnect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the Electronic Control Unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to Program/Reprogram. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 6725 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 6731 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Seals and Gaskets: All Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 6736 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 6737 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 6738 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 6739 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 05-08-49-018A > May > 06 > Instruments - Service Tire Monitor Message is Displayed Low Tire Pressure Indicator: All Technical Service Bulletins Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 6745 Seals and Gaskets: By Symptom Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 6746 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 6747 To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E Seals and Gaskets: Service and Repair Automatic Transmission - 4L80-E/4L85-E Filler Tube and Seal Replacement Filler Tube and Seal Replacement Removal Procedure 1. Remove the oil level indicator. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Remove the fill tube bracket nut. 4. Place a drain pan under the transmission. 5. Remove the fill tube. 6. Remove the transmission fill tube seal. Installation Procedure 1. Install the transmission fill tube seal. 2. Install the fill tube. 3. Remove the drain pan from under the transmission. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6750 4. Install the fill tube bracket nut. 5. Lower the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the oil level indicator. ^ Tighten the nut to 47 Nm (35 ft. lbs.). 7. Fill the transmission to the proper level with Dexron® III transmission fluid. Manual Shift Shaft Seal Replacement Manual Shift Shaft Seal Replacement ^ Tools Required J 43911 Selector Shaft Seal Remover - J 43909 Selector Shaft Seal Installer Removal Procedure 1. Remove the park/neutral position (PNP) switch. 2. Ensure that the jackscrew for J 43911 is backed off and will not interfere with installation of the removal tool. Slide the seal remover tool over the selector shaft (2) with the threaded end of the tool towards the seal. 3. Rotate the J 43911 so that the threads on the end of the tool engage the steel shell (1) of the seal. Use a wrench to be sure that the removal tool is firmly attached to the seal shell. 4. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed. Installation Procedure 1. Carefully slide a new selector shaft seal (1) over the selector shaft (2) with the wide face of the steel case facing outward. Position the seal so that it is starting to enter the seal bore. 2. Using J 43909, remove the inner sleeve so that the tool will slide over the selector shaft. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6751 3. Slide the J 43909 into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the J 43909 and drive the new seal into the seal bore until it is seated at the bottom of the bore. 4. Install the PNP switch. 5. Fill the transmission to the proper level with DEXRON® III transmission fluid. Transmission Extension Housing Rear Oil Seal Replacement Transmission Extension Housing Rear Oil Seal Replacement ^ Tools Required J 41505 Output Shaft Seal Installer - J 6125-1BSlide Hammer - J 23129 Universal Seal Remover - J 36850 Transmission Assembly Lubricant Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the vehicle. 3. Remove the propeller shaft. 4. Using the J 6125-1B (1) and the J 23129 (2), remove the output shaft seal (3) from the extension housing (4). 5. Inspect the case extension housing for damage. Replace the extension housing if necessary. Installation Procedure 1. Lubricate the inside diameter of the new seal with J 36850. 2. Use the J 41505 (1) with a soft faced mallet to install the seal (2). 3. Install the seal (2) to the extension housing (3). 4. Install the propeller shaft. 5. Remove the drain pan and lower the vehicle. 6. Fill the transmission to the proper level with Dexron® III transmission fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6752 Seals and Gaskets: Service and Repair Automatic Transmission - Allison PTO Cover Gasket Replacement PTO Cover Gasket Replacement Removal Procedure 1. Remove 6 bolts (3). 2. Remove the power take-off (PTO) cover (2) and gasket (1). Discard the used gasket. 3. Ensure the PTO gasket face on the main housing is free of all foreign material, nicks and scratches. Installation Procedure 1. Install the new PTO cover gasket (1) and cover (2). 2. Notice: Refer to Fastener Notice in Service Precautions. Start the top-center bolt (3) first. Install the other 5 bolts. ^ Tighten all bolts to 43 Nm (32 ft. lbs.). Torque Converter Housing Bolt Seal Replacement Torque Converter Housing Bolt Seal Replacement Removal Procedure 1. Remove the torque converter from the transmission. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6753 2. Remove any of ten bolts (1) (bolt heads shaded) where leakage at the bolt head is suspected. 3. Important: Bolts (1) have a removable seal under the flanged head. Remove and discard seals from bolts removed. Installation Procedure 1. Install new seals on any bolts (1) removed. 2. Notice: Refer to Fastener Notice in Service Precautions. Install any bolts (1) removed. ^ Tighten bolts to 56 Nm (41 ft. lbs.). 3. Install the torque converter into the transmission. Filler Tube and Seal Replacement Filler Tube and Seal Replacement Removal Procedure 1. The transmission case has provisions that enable the fill tube to be installed on either the right or left side of the transmission. Proceed to step 9 if servicing the plug and/or seal opposite the fill tube. 2. If the vehicle is equipped with a diesel engine, the transmission must be removed to service the fill tube and/or seal. 3. Remove the transmission fluid level indicator. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Remove the fill tube nuts. 6. Place a drain pan under the transmission to catch any dripping fluid. 7. Loosen the fill tube from the transmission. 8. Remove the fill tube and seal from the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6754 9. Remove the fill tube plug (1). 10. Remove the fill tube plug seal (2). Installation Procedure 1. Install a new fill tube plug seal (2) into the main housing. 2. Align the tab on the fill tube plug (1) with the tang on the main housing. 3. Install the fill tube plug (1). Press the plug into the seal (2) until the tab on the fill tube plug locks into place in the notch on the main housing. 4. Install a NEW fill tube seal. 5. Install the fill tube. Ensure that the fill tube bracket is positioned properly on the studs. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the fill tube nuts. ^ Tighten the nuts to 18 Nm (13 ft. lbs.). 7. Lower the vehicle. 8. Fill the transmission to the proper level with approved fluid. Seal Replacement - Torque Converter Seal Replacement - Torque Converter ^ Tools Required J 24171-A Seal and Dust Shield Remover - J 43772 Torque Converter Seal Installer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6755 Removal Procedure 1. Remove the torque converter from the transmission. 2. Obtain J 24171-A and install the tip (3) with a 90 degree hook onto the end of the slide-hammer (1). 3. Position the 90 degree hook behind the rear face of the seal outer case (2). Remove the torque converter seal using the slide-hammer. 4. Inspect the seal bore for scratches. Remove any scratches in the seal bore using crocus cloth. Installation Procedure 1. Install the new seal (2) onto the J 43772. Position the seal so the seal lip is outward and the face of the steel case is against the driving face (1) on the tool. 2. Slide the installer tool over the turbine shaft and ground sleeve until the seal starts into the seal bore. Strike the installer tool with mallet (1) to drive the seal into the seal bore. The seal is installed correctly when the shoulder of the installer tool squarely contacts the outer surface of the oil pump. 3. Install the torque converter into the transmission. Seal Replacement - Rear Propshaft Seal Replacement - Rear Propshaft ^ Tools Required J 24171-A Seal and Dust Shield Remover - J 43782 Rear Seal Installer Removal Procedure 1. Remove the yoke assembly from the transmission. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6756 2. Obtain J 24171-A and install a 90 degree hook onto the end of the slide-hammer (1). 3. Position the 90 degree hook behind the rear face of the seal's outer case (2). 4. Remove the rear seal using the slide-hammer. 5. Inspect the seal bore for scratches. Remove any scratches in the seal bore using crocus cloth. Installation Procedure 1. Important: Be sure the new seal has blue sealant coating the OD (4). This identifies the seal for use in the 1000 Series transmissions. The blue sealant identification is important because the 1000 Series transmissions have an overdrive ratio in fifth range and there is a potential for high output shaft speeds and resultant high seal temperature. Align the seal so the seal lip (2) is outward and the face of the steel case (1) will be against the driving face (3) of the tool. Install the new seal onto J 43782. 2. Slide the installer tool over the output shaft until the seal enters the seal bore. Strike the installer tool with a mallet (1) to drive the seal into the seal bore. The seal is installed correctly when the shoulder of the installer tool squarely contacts the outer surface of the rear cover. 3. Install the yoke assembly onto the transmission. Selector Shaft Seal Replacement Selector Shaft Seal Replacement ^ Tools Required J 43911 Selector Shaft Seal Remover - J 43909 Selector Shaft Seal Installer Removal Procedure 1. Remove the Park/Neutral Position (PNP) Switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6757 2. Be sure that the jackscrew for J 43911 is backed off and will not interfere with installation of the removal tool. Slide the seal remover tool over the selector shaft (2) with the threaded end of the tool towards the seal. 3. Rotate the removal tool so that the threads on the end of the tool engage the steel shell (1) of the seal. Use a wrench to be sure that the removal tool is firmly attached to the seal shell. 4. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed. Installation Procedure 1. Carefully slide a new selector shaft seal (1) over the selector shaft (2) with the wide face of the steel case facing outward. Position the seal so that it is starting to enter the seal bore. 2. Obtain J 43909 and remove the inner sleeve so that the tool will slide over the selector shaft. 3. Slide the J 43909 into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the J 43909 and drive the new seal into the seal bore until it is seated at the bottom of the bore. 4. Install the PNP Switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions Brake Switch - TCC: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6763 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6764 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6765 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6766 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6767 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6768 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6769 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6770 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6771 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6772 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6773 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6774 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6775 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6776 Brake Switch - TCC: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6777 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6778 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6779 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6780 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6781 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6782 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6783 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6784 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6785 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6786 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6787 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6788 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6789 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6790 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6791 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6792 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6793 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6794 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6795 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6796 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6797 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6798 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6799 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6800 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6801 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6802 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6803 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6804 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6805 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6806 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6807 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6808 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6809 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6810 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6811 Power, Ground and Brake Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Component Locations Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Component Locations > Page 6816 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 6817 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 6818 Fluid Pressure Sensor/Switch: Service and Repair Pressure Switch Manifold Replacement Removal Procedure 1. Important: Individual pressure switches cannot be replaced. When any pressure switch needs replacing, the entire assembly must be replaced. Important: The G solenoid has been removed for clarity. Remove the oil pan and suction filter. 2. Remove the two bolts (2). Remove the reverse signal tube (1). 3. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the internal wiring harness connector from the pressure switch assembly (2). 4. Remove five bolts (1). Remove the pressure switch assembly (2). Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 6819 1. Notice: Refer to Fastener Notice in Service Precautions. Place the new pressure switch manifold assembly (2) in position and install one bolt (1) in a recessed location to hold it into position. Start the remaining four bolts (1) in recessed locations and tighten the bolts by hand. Torque the bolts to 12 Nm (108 inch lbs.). 2. Connect the internal wiring harness connector to the pressure switch assembly. 3. Install the reverse signal tube (1). Install two bolts (2). ^ Tighten the bolts to 12 Nm (108 inch lbs.). 4. Install the oil pan and suction filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch: Testing and Inspection 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 6824 Steps 1-9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 6825 Tow/Haul Switch: Testing and Inspection 4L80-E/4L85-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between up shifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit checks are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 6826 Steps 1-9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start Transmission Position Switch/Sensor: Customer Interest A/T - Slow/No Gear Engagement/Engine No Start Bulletin No.: 02-07-30-011C Date: June 21, 2004 TECHNICAL Subject: Slow or No Engagement of Automatic Transmission, No Start, Blank PRNDL Display, Flashing PRNDL, DTC P0708, P0872, P0847, P0875, P1711, P1713 or U1000 Set (Diagnose Condition, Repair According to Procedure) Models: 2001-2004 Chevrolet Silverado 2001-2004 GMC Sierra with Allison(R) LCT1000 Automatic Transmission (RPO M74) and 6.6L Duramax(TM) Diesel Engine (RPO LB7) or 8.1L Gas Engine (RPO L18) Supercede: This bulletin is being revised to add model years and additional model information and add graphics. Please discard Corporate Bulletin Number 02-07-30-011B (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions. ^ The PRNDL display is flashing. ^ The engine will not start. ^ The "Service Engine Soon" Indicator lamp is illuminated. ^ The transmission does not shift properly. ^ The vehicle will not move, transmission will not engage. Cause Moisture contamination within the Park Neutral Position (PNP) Switch may cause this condition. This is sometimes referred to as the Neutral Start Back-up (NSBU) Switch. On a left turn, water spray from the left front tire is directed directly at this switch. Proper installation of the "Front Shield" and "Rear Shield" are essential for proper repairs. Technician Diagnosis This bulletin ONLY applies to vehicles equipped with a two connector PNP switch as shown above. A complete and through diagnosis must be performed by a qualified electrical technician to determine the cause and avoid needless replacement of good components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 6835 Important: The Transmission Control Module (TCM) and or the Pressure Switch Manifold (PSM) should NOT be replaced unless properly diagnosed. They are probably not the cause of the concern. It is often assumed the module is the cause of the concern when, in fact, it is another component or the wiring between the components that causes the concern. Important: Remember, everything starts with a properly operating Neutral Start Back Up (NSBU) switch. The NSBU switch has been incorporated into what is now called the Park Neutral Position (PNP) switch. If the PNP switch does not provide the proper voltage signal to the module indicating the transmission is in either Park or Neutral, the module will not allow the starter operation. After the engine is started, and the shift lever is moved to either Reverse or one of the drive positions, the range selected portion of the PNP switch portion provides a voltage input to the module as to what range the driver has manually selected for transmission operation. The module then controls pressures, shift points and other transmission functions based on the voltage input received from the range portion of the PNP switch. The technician may find one or more of the following conditions. The list of these conditions does not imply any type of frequency or order. They are random events and may occur in any order. ^ DTC P0708, Neutral start/backup (PNP or NSBU) switch ^ DTC P0847, Pressure Switch Manifold (PSM) ^ DTC P0872, Pressure Switch Manifold (PSM) ^ DTC P0875, Pressure Switch Manifold (PSM) ^ DTC P1711, Pressure Switch Manifold (PSM) ^ DTC P1713, Pressure Switch Manifold (PSM) ^ DTC U1000, Serial Data Communications ^ Blank PRNDL Display ^ Flashing PRNDL Display ^ Slow or No Engagement of Automatic Transmission Blank PRNDL Display A blank PRNDL display may indicate a condition with the PNP switch and/or one or more of the four signal circuits from the PNP to the TCM. 1. Pin A, Circuit 771 (BLK/WHT) 2. Pin B, Circuit 773 (GRA) 3. Pin C, Circuit 776 (WHT) 4. Pin D, Circuit 772 (YEL) Or, a blank PRNDL display may also occur if an out of line condition exists with the Serial Data Circuit (CKT 2470, yellow wire) from the TCM to Splice Pack 205. Diagnostic Tip 1. Connect the Tech 2(R) to the vehicle. 2. Power up the Tech 2(R). 3. Does the Tech 2(R) communicate with the TCM? If not, inspect the serial data circuit, CKT 2470 (Yellow wire), between the TCM and Splice Pack 205. Specifically inspect connector C106, a five terminal connector located below the left side underhood bussed electrical center, directly beneath the red battery cable terminal connection. Perform a mating terminal pull test on all of the terminals in this connector. Repair as required. 4. Observe the Gear Selected screen on the scan tool. The following values should be shown on the Tech 2(R) display and the vehicle's instrument panel cluster (if equipped with the I/P display). ^ "8" (shifter should be in the Park position) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 6836 ^ "7" (shifter should be in the Reverse position) ^ "5" (shifter should be in the Drive position) ^ "3" (shifter should be in the Third gear position) ^ "2" (shifter should be in the Second gear position) ^ "1" (shifter should be in the First gear position) ^ "0" (shifter should be in the Neutral Position) If the Gear Selected display does not match the shifter position in the vehicle, diagnose using one of the following methods. ^ Obtain a new PNP switch kit, P/N 29540479, from the Parts Department. ^ 0.1. Disconnect the wiring connector from the original transmission mounted PNP switch. ^ 0.2. Connect the new switch to the wiring connector. ^ 0.3. Return to Step # 4 above and observe the display as you rotate the switch. If all positions indicate properly, refer to the Correction section below. ^ Use the DTC P0708 diagnostic chart in Service Information (SI) under Transmission/Transaxle/Automatic Transmission - Allison. Reference SI Document ID # 769549 for the wiring schematic for this symptom. The PNP switch, as referenced in SI, is known as the NSBU switch in the Parts information. It is now serviced with a Park Neutral Position Switch Kit, P/N 29540479. Flashing PRNDL Display A flashing PRNDL display may be the result of incorrect sensor inputs or transmission abuse protection modes being received by the TCM. The following are some of these conditions: ^ The transfer case is/was in Neutral. ^ The transfer case is/was shifted into Neutral when the vehicle is moving. ^ A decrease of the input turbine speed was not detected when the gear selector was moved into any gear. ^ A low transmission fluid level. ^ A misadjusted PNP/NSBU switch. ^ Turbine input speed or output speed sensor failure. ^ Failures of the shift solenoids to route the transmission oil to the proper clutch assemblies within the transmission. ^ Failures of the transmission clutch packs (C1 or C5 for first gear, C3 or C5 for Reverse). ^ Failure to detect proper line pressures when a gear range is selected, which may be the result of normal maintenance such as a transmission fluid change having been completed, or the transmission pan was removed for a filter replacement or other type service. Transmission abuse protection modes are encountered when a customer performs one of the following types of maneuvers: ^ Shifting from Neutral to Drive/Reverse when the engine RPM is greater than 1400 RPM. ^ Shifting from Drive to Reverse when the throttle position (TPS) is greater than 25%, such as rocking the vehicle when stuck in an attempt to free the vehicle. ^ When the transmission output speed is greater than 300 RPM from attempted changes in direction such as Reverse to Drive, Drive to Reverse or Neutral to Reverse shifts. When the TCM encounters any one of the above conditions, the TCM will flash the PRNDL and default the transmission to Neutral. A flashing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 6837 PRNDL indicates something is/was incorrect. The transmission may need the attention of a qualified service technician. Correction 1. Disconnect the wiring harness from the PNP switch. 2. Disconnect the shift linkage/cable from the shift lever at the transmission. 3. With a wrench keeping the shift lever from rotating, remove the nut from the end of the selector shaft. 4. Use a file to remove any burrs or raised metal where the selector lever was seated against the shoulder of the selector shaft. Important: If the old PNP switch will not slide from the selector shaft without the effort, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 5. Remove the two bolts that attach the PNP switch and remove the switch by sliding it outward over the selector shaft. 6. Make sure the selector shaft is in the N (neutral) position (using a wrench on the selector shaft flats, rotate the shaft to its furthest clockwise position and then rotate counterclockwise two detents). Important: If the new PNP switch will not slide onto the selector shaft easily, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 7. Slide the new PNP switch over the selector shaft with the neutral assurance bracket 920 facing outward and maintaining the correct PNP switch orientation to the selector shaft. Install and hand tighten the two PNP switch attaching bolts so that the PNP switch and bracket may be rotated within the adjusting slots with some effort. 8. While holding the neutral assurance bracket in engagement with the PNP switch, tighten the two bolts that attach the PNP switch to the transmission case. Tighten Tighten the bolts to 27 N.m (20 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 6838 9. Remove and discard the neutral assurance bracket. Important: Installation of the front shield and rear shields are important. Without proper installation of the shield, a return repair is probable. Follow all directions as listed on the installation instructions sheet included in the Switch kit, P/N 29540479. 10. Fit the new shield onto the PNP switch so that it fits securely against the switch. Make sure this is done before reinstalling the shift lever. 11. Reinstall the shift lever. With a wrench keeping the shift lever from rotating, install the nut on the end of the selector shaft. Tighten. Tighten the nut to 24 N.m (18 lb ft). 12. Connect the wiring harness connectors to the PNP switch. 13. Attach the selector cable to the lever. Check and adjust if needed. 14. Go back to step 4 of the Diagnostics and insure the Tech 2 readings match the shift lever positions. Important: Clear all DTCs before returning the vehicle to the customer. 15. Return the vehicle to the customer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 6839 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Slow/No Gear Engagement/Engine No Start Bulletin No.: 02-07-30-011C Date: June 21, 2004 TECHNICAL Subject: Slow or No Engagement of Automatic Transmission, No Start, Blank PRNDL Display, Flashing PRNDL, DTC P0708, P0872, P0847, P0875, P1711, P1713 or U1000 Set (Diagnose Condition, Repair According to Procedure) Models: 2001-2004 Chevrolet Silverado 2001-2004 GMC Sierra with Allison(R) LCT1000 Automatic Transmission (RPO M74) and 6.6L Duramax(TM) Diesel Engine (RPO LB7) or 8.1L Gas Engine (RPO L18) Supercede: This bulletin is being revised to add model years and additional model information and add graphics. Please discard Corporate Bulletin Number 02-07-30-011B (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions. ^ The PRNDL display is flashing. ^ The engine will not start. ^ The "Service Engine Soon" Indicator lamp is illuminated. ^ The transmission does not shift properly. ^ The vehicle will not move, transmission will not engage. Cause Moisture contamination within the Park Neutral Position (PNP) Switch may cause this condition. This is sometimes referred to as the Neutral Start Back-up (NSBU) Switch. On a left turn, water spray from the left front tire is directed directly at this switch. Proper installation of the "Front Shield" and "Rear Shield" are essential for proper repairs. Technician Diagnosis This bulletin ONLY applies to vehicles equipped with a two connector PNP switch as shown above. A complete and through diagnosis must be performed by a qualified electrical technician to determine the cause and avoid needless replacement of good components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 6845 Important: The Transmission Control Module (TCM) and or the Pressure Switch Manifold (PSM) should NOT be replaced unless properly diagnosed. They are probably not the cause of the concern. It is often assumed the module is the cause of the concern when, in fact, it is another component or the wiring between the components that causes the concern. Important: Remember, everything starts with a properly operating Neutral Start Back Up (NSBU) switch. The NSBU switch has been incorporated into what is now called the Park Neutral Position (PNP) switch. If the PNP switch does not provide the proper voltage signal to the module indicating the transmission is in either Park or Neutral, the module will not allow the starter operation. After the engine is started, and the shift lever is moved to either Reverse or one of the drive positions, the range selected portion of the PNP switch portion provides a voltage input to the module as to what range the driver has manually selected for transmission operation. The module then controls pressures, shift points and other transmission functions based on the voltage input received from the range portion of the PNP switch. The technician may find one or more of the following conditions. The list of these conditions does not imply any type of frequency or order. They are random events and may occur in any order. ^ DTC P0708, Neutral start/backup (PNP or NSBU) switch ^ DTC P0847, Pressure Switch Manifold (PSM) ^ DTC P0872, Pressure Switch Manifold (PSM) ^ DTC P0875, Pressure Switch Manifold (PSM) ^ DTC P1711, Pressure Switch Manifold (PSM) ^ DTC P1713, Pressure Switch Manifold (PSM) ^ DTC U1000, Serial Data Communications ^ Blank PRNDL Display ^ Flashing PRNDL Display ^ Slow or No Engagement of Automatic Transmission Blank PRNDL Display A blank PRNDL display may indicate a condition with the PNP switch and/or one or more of the four signal circuits from the PNP to the TCM. 1. Pin A, Circuit 771 (BLK/WHT) 2. Pin B, Circuit 773 (GRA) 3. Pin C, Circuit 776 (WHT) 4. Pin D, Circuit 772 (YEL) Or, a blank PRNDL display may also occur if an out of line condition exists with the Serial Data Circuit (CKT 2470, yellow wire) from the TCM to Splice Pack 205. Diagnostic Tip 1. Connect the Tech 2(R) to the vehicle. 2. Power up the Tech 2(R). 3. Does the Tech 2(R) communicate with the TCM? If not, inspect the serial data circuit, CKT 2470 (Yellow wire), between the TCM and Splice Pack 205. Specifically inspect connector C106, a five terminal connector located below the left side underhood bussed electrical center, directly beneath the red battery cable terminal connection. Perform a mating terminal pull test on all of the terminals in this connector. Repair as required. 4. Observe the Gear Selected screen on the scan tool. The following values should be shown on the Tech 2(R) display and the vehicle's instrument panel cluster (if equipped with the I/P display). ^ "8" (shifter should be in the Park position) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 6846 ^ "7" (shifter should be in the Reverse position) ^ "5" (shifter should be in the Drive position) ^ "3" (shifter should be in the Third gear position) ^ "2" (shifter should be in the Second gear position) ^ "1" (shifter should be in the First gear position) ^ "0" (shifter should be in the Neutral Position) If the Gear Selected display does not match the shifter position in the vehicle, diagnose using one of the following methods. ^ Obtain a new PNP switch kit, P/N 29540479, from the Parts Department. ^ 0.1. Disconnect the wiring connector from the original transmission mounted PNP switch. ^ 0.2. Connect the new switch to the wiring connector. ^ 0.3. Return to Step # 4 above and observe the display as you rotate the switch. If all positions indicate properly, refer to the Correction section below. ^ Use the DTC P0708 diagnostic chart in Service Information (SI) under Transmission/Transaxle/Automatic Transmission - Allison. Reference SI Document ID # 769549 for the wiring schematic for this symptom. The PNP switch, as referenced in SI, is known as the NSBU switch in the Parts information. It is now serviced with a Park Neutral Position Switch Kit, P/N 29540479. Flashing PRNDL Display A flashing PRNDL display may be the result of incorrect sensor inputs or transmission abuse protection modes being received by the TCM. The following are some of these conditions: ^ The transfer case is/was in Neutral. ^ The transfer case is/was shifted into Neutral when the vehicle is moving. ^ A decrease of the input turbine speed was not detected when the gear selector was moved into any gear. ^ A low transmission fluid level. ^ A misadjusted PNP/NSBU switch. ^ Turbine input speed or output speed sensor failure. ^ Failures of the shift solenoids to route the transmission oil to the proper clutch assemblies within the transmission. ^ Failures of the transmission clutch packs (C1 or C5 for first gear, C3 or C5 for Reverse). ^ Failure to detect proper line pressures when a gear range is selected, which may be the result of normal maintenance such as a transmission fluid change having been completed, or the transmission pan was removed for a filter replacement or other type service. Transmission abuse protection modes are encountered when a customer performs one of the following types of maneuvers: ^ Shifting from Neutral to Drive/Reverse when the engine RPM is greater than 1400 RPM. ^ Shifting from Drive to Reverse when the throttle position (TPS) is greater than 25%, such as rocking the vehicle when stuck in an attempt to free the vehicle. ^ When the transmission output speed is greater than 300 RPM from attempted changes in direction such as Reverse to Drive, Drive to Reverse or Neutral to Reverse shifts. When the TCM encounters any one of the above conditions, the TCM will flash the PRNDL and default the transmission to Neutral. A flashing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 6847 PRNDL indicates something is/was incorrect. The transmission may need the attention of a qualified service technician. Correction 1. Disconnect the wiring harness from the PNP switch. 2. Disconnect the shift linkage/cable from the shift lever at the transmission. 3. With a wrench keeping the shift lever from rotating, remove the nut from the end of the selector shaft. 4. Use a file to remove any burrs or raised metal where the selector lever was seated against the shoulder of the selector shaft. Important: If the old PNP switch will not slide from the selector shaft without the effort, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 5. Remove the two bolts that attach the PNP switch and remove the switch by sliding it outward over the selector shaft. 6. Make sure the selector shaft is in the N (neutral) position (using a wrench on the selector shaft flats, rotate the shaft to its furthest clockwise position and then rotate counterclockwise two detents). Important: If the new PNP switch will not slide onto the selector shaft easily, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 7. Slide the new PNP switch over the selector shaft with the neutral assurance bracket 920 facing outward and maintaining the correct PNP switch orientation to the selector shaft. Install and hand tighten the two PNP switch attaching bolts so that the PNP switch and bracket may be rotated within the adjusting slots with some effort. 8. While holding the neutral assurance bracket in engagement with the PNP switch, tighten the two bolts that attach the PNP switch to the transmission case. Tighten Tighten the bolts to 27 N.m (20 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 6848 9. Remove and discard the neutral assurance bracket. Important: Installation of the front shield and rear shields are important. Without proper installation of the shield, a return repair is probable. Follow all directions as listed on the installation instructions sheet included in the Switch kit, P/N 29540479. 10. Fit the new shield onto the PNP switch so that it fits securely against the switch. Make sure this is done before reinstalling the shift lever. 11. Reinstall the shift lever. With a wrench keeping the shift lever from rotating, install the nut on the end of the selector shaft. Tighten. Tighten the nut to 24 N.m (18 lb ft). 12. Connect the wiring harness connectors to the PNP switch. 13. Attach the selector cable to the lever. Check and adjust if needed. 14. Go back to step 4 of the Diagnostics and insure the Tech 2 readings match the shift lever positions. Important: Clear all DTCs before returning the vehicle to the customer. 15. Return the vehicle to the customer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 6849 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 6850 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 6851 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission 4L80-E/4L85-E Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission 4L80-E/4L85-E > Page 6854 Transmission Position Switch/Sensor: Adjustments Automatic Transmission - Allison Park/Neutral Position Switch Adjustment ^ Tools Required J 41364-A PNP Switch Adjusting Tool Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Make sure the selector shaft is in the N (Neutral) position as follows: ^ Place a wrench on the selector shaft flats and rotate the shaft to its furthest clockwise position. ^ Rotate the selector shaft counter-clockwise two detents. 2. Be sure that J 41364-A (2) is in the proper position on PNP switch (1). 3. While maintaining the correct PNP switch-to-selector-shaft alignment, slide the new PNP switch (5) over the selector shaft (4). 4. Notice: Refer to Component Fastener Tightening Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission 4L80-E/4L85-E > Page 6855 While holding J 41364-A in engagement with the PNP switch, install the two bolts (6) so that the PNP switch may be rotated with some effort. ^ Tighten the two bolts (6) to 27 Nm (20 ft. lbs.). 5. Remove J 41364-A. 6. Install splash shield (1), concave side toward PNP switch (3), over selector shaft (2). 7. Notice: Refer to Transmission Selector Shaft Abuse Notice in Service Precautions. Reinstall Shift Lever (2). Install nut (3), by hand, on the end of selector shaft (4). Use a wrench (1) to keep the shift lever from rotating. ^ Tighten nut (3) to 24 Nm (18 ft. lbs.) 8. Reconnect the shift selector linkage/cable to the shift lever (2). 9. Connect the external wiring harness to the PNP switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission 4L80-E/4L85-E Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L80-E/4L85-E Park/Neutral Position Switch Replacement Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission 4L80-E/4L85-E > Page 6858 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission 4L80-E/4L85-E > Page 6859 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission 4L80-E/4L85-E > Page 6860 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Park Lock Pawl and Actuator Replacement Park Lock Pawl and Actuator Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the park/neutral position (PNP) switch. 3. Remove the manual shaft nut and pin. 4. Remove the detent lever and actuator. 5. Remove the parking pawl bracket bolts. 6. Remove the parking pawl return spring. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission 4L80-E/4L85-E > Page 6861 7. Use the modified screw extractor in order to remove the plug. 8. Remove the parking pawl shaft retainer, shaft and pawl. 9. Important: If the manual shaft binds in the case during removal, file or sand the shaft in the area adjacent to the detent lever. Remove the manual shaft. 10. Remove the manual shaft seal. Installation Procedure 1. Install the pawl shaft. 2. Install the parking pawl. 3. Install the plug using a 8 mm or (5/16 inch) rod with Loctite® or equivalent. 4. Install the retainer. 5. Install the pawl return spring. 6. Install the detent lever to the actuator. 7. Install the actuator over the parking pawl. 8. Install the manual shaft seal. 9. Lubricate the manual shaft with transmission oil and install the manual shaft into the case. 10. Install the nut on the shaft. 11. Install the roll pin. 12. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission 4L80-E/4L85-E > Page 6862 Install the parking lock bracket bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 13. Install the PNP switch. 14. Install the transmission filter. 15. Fill the transmission to the proper level with Dexron® III transmission fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission 4L80-E/4L85-E > Page 6863 Transmission Position Switch/Sensor: Service and Repair Automatic Transmission - Allison Park/Neutral Position Switch Replacement PNP Switch Removal Refer to Park/Neutral Position Switch Removal. PNP Switch Install Refer to Park/Neutral Position Switch Installation. 7. Notice: Refer to Transmission Selector Shaft Abuse Notice in Service Precautions. Reinstall shift lever (2). Install nut (3), by hand, on the end of selector shaft (4). Use a wrench (1) to keep the shift lever from rotating. ^ Tighten nut (3) to 24 Nm (18 ft. lbs.). 8. Reconnect the shift selector linkage/cable to the shift lever (2). 9. Connect the external wiring harness to the PNP switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Electrical Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Electrical Specifications > Page 6868 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 6869 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E Transmission Speed Sensor: Diagrams Automatic Transmission - 4L80-E/4L85-E Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 6872 Transmission Speed Sensor: Diagrams Automatic Transmission - Allison Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 6873 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission 4L80-E/4L85-E Transmission Speed Sensor: Service and Repair Automatic Transmission - 4L80-E/4L85-E Input Shaft Speed Sensor Replacement Input Shaft Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1). 5. Inspect the input speed sensor (1) for any evidence of damage. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission 4L80-E/4L85-E > Page 6876 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the input speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector (1). 5. Lower the vehicle. Output Shaft Speed Sensor Replacement Output Shaft Speed Sensor Replacement Removal Procedure Important: This procedure is for 2-wheel drive (2WD) vehicles only. If the vehicle is equipped with 4-wheel drive (4WD), the output speed sensor is located on the transfer case. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission 4L80-E/4L85-E > Page 6877 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2). 5. Inspect the output speed sensor (2) for any evidence of damage. Installation Procedure 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the output speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission 4L80-E/4L85-E > Page 6878 4. Connect the output speed sensor (2) electrical connector. 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission 4L80-E/4L85-E > Page 6879 Transmission Speed Sensor: Service and Repair Automatic Transmission - Allison Speed Sensor Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Be sure the vehicle ignition is turned off. 2. Disconnect the external wiring harness from the speed sensor. 3. Remove the bolt (1) from the speed sensor and carefully remove the speed sensor (2). Installation Procedure 1. Important: Do not rotate the sensor in its retaining bracket. Changing the sensor/bracket orientation may cause improper operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission 4L80-E/4L85-E > Page 6880 Install a new a O-ring (3) on the speed sensor (2). Lubricate the O-ring with clean transmission fluid. 2. Install the new speed sensor (2) into the speed sensor bore. Align the hole in the retaining bracket with the bolt hole in the speed sensor boss. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor bolt (1). ^ Tighten bolt (1) to 12 Nm (108 inch lbs.). 4. Reconnect the external wiring harness to the speed sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Electrical Specifications Transmission Temperature Sensor/Switch: Electrical Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Electrical Specifications > Page 6885 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Electrical Specifications > Page 6886 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Component Locations Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Component Locations > Page 6889 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 6894 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure 1. Caution: Refer to SIR Caution in Service Precautions. Disable the SIR system. 2. Remove the body control module (BCM). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 6895 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the BCM. 6. Enable the SIR system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Electrical Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Electrical Specifications > Page 6900 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 6901 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E Shift Solenoid: Diagrams Automatic Transmission - 4L80-E/4L85-E Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 6904 Shift Solenoid: Diagrams Automatic Transmission - Allison Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 6905 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 6906 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 6907 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 6908 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 6909 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 6910 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. Remove the 1-2 accumulator, if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 6911 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 6912 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Notice: Refer to Fastener Notice in Service Precautions. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 6913 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair Selector Shaft: Service and Repair Selector Shaft and Detent Lever Replacement Removal Procedure 1. Remove the control valve assembly from the transmission. 2. Remove the PNP switch. 3. Loosen nut (1) on the selector shaft (5) that retains the detent lever (4) to the selector shaft. 4. Important: DO NOT mar the main housing surface around the spring pin when removing the spring pin. An unmarred surface is required to maintain the seal between the control valve assembly and the main housing. Place a protective plate on the main housing surface around the spring pin (3). Place a drill bit inside spring pin (3) to prevent cutting or collapsing the pin when removing the pin. Remove the spring pin (3) from the main housing. 5. Slide the selector shaft (5) through the detent lever (4) and through the selector shaft seal. 6. Rotate the detent lever to disengage the park pawl apply assembly (2). Remove the detent lever (4) and nut (1). Installation Procedure 1. Place the new detent lever (4) in position in the main housing. Rotate the detent lever to engage the park pawl apply assembly (2). .Reinstall the selector shaft (5) through the selector shaft seal and through the detent lever (4). 2. Notice: Refer to Fastener Notice in Service Precautions. Place the nut (1) in position over the selector shaft. Push the selector shaft (5) into its final position in the main housing. Reinstall the spring pin (3) into the main housing that retains the selector shaft. Install pin to 8.5-9.0 mm (0.33-0.35 inch) above main housing surface. Hand tighten nut (1). ^ Tighten the nut (1) to 29 Nm (21 ft. lbs.). 3. Install the PNP switch. 4. Install the control valve assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-018B > Feb > 07 > A/T - Cannot Shift After Driving in Ice/Snow Shift Cable: Customer Interest A/T - Cannot Shift After Driving in Ice/Snow Bulletin No.: 04-07-30-018B Date: February 09, 2007 INFORMATION Subject: Availability of Transmission Shield to Protect Shift Cable/Manual Shaft Area from Snow and Ice Build-Up On Allison Automatic Transmissions Models: 2001-2005 Light Duty Trucks with Allison(R) Automatic Transmission Supercede: This bulletin is being revised to remove 2006 model year vehicles. Please discard Corporate Bulletin Number 04-07-30-01 8A (Section 07 - Transmission/Transaxle). This bulletin is to inform dealers that some vehicles may exhibit an inability to shift the transmission after operating in slush, snow or icy conditions. Investigation may show a build-up of ice on the transmission around the shift cable to manual shaft connection. A transmission shield that will protect the shift cable/manual shaft area from snow and ice build-up is available through aftermarket automotive parts suppliers. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-018B > Feb > 07 > A/T - Cannot Shift After Driving in Ice/Snow > Page 6926 The transmission shield, P/N 700028, will protect the shift cable/manual shaft area from snow and ice build-up. Installation of this shield is not considered to be warranty. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-018B > Feb > 07 > A/T - Cannot Shift After Driving in Ice/Snow > Page 6927 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-018B > Feb > 07 > A/T - Cannot Shift After Driving in Ice/Snow > Page 6928 This shield is NOT available through GMSPO and must be purchased from a distributor. Warranty Information Addition of the shield is NOT a warrantable repair. The information shown is a suggested repair guide only. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-018B > Feb > 07 > A/T - Cannot Shift After Driving in Ice/Snow > Page 6929 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-018B > Feb > 07 > A/T - Cannot Shift After Driving in Ice/Snow Shift Cable: All Technical Service Bulletins A/T - Cannot Shift After Driving in Ice/Snow Bulletin No.: 04-07-30-018B Date: February 09, 2007 INFORMATION Subject: Availability of Transmission Shield to Protect Shift Cable/Manual Shaft Area from Snow and Ice Build-Up On Allison Automatic Transmissions Models: 2001-2005 Light Duty Trucks with Allison(R) Automatic Transmission Supercede: This bulletin is being revised to remove 2006 model year vehicles. Please discard Corporate Bulletin Number 04-07-30-01 8A (Section 07 - Transmission/Transaxle). This bulletin is to inform dealers that some vehicles may exhibit an inability to shift the transmission after operating in slush, snow or icy conditions. Investigation may show a build-up of ice on the transmission around the shift cable to manual shaft connection. A transmission shield that will protect the shift cable/manual shaft area from snow and ice build-up is available through aftermarket automotive parts suppliers. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-018B > Feb > 07 > A/T - Cannot Shift After Driving in Ice/Snow > Page 6935 The transmission shield, P/N 700028, will protect the shift cable/manual shaft area from snow and ice build-up. Installation of this shield is not considered to be warranty. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-018B > Feb > 07 > A/T - Cannot Shift After Driving in Ice/Snow > Page 6936 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-018B > Feb > 07 > A/T - Cannot Shift After Driving in Ice/Snow > Page 6937 This shield is NOT available through GMSPO and must be purchased from a distributor. Warranty Information Addition of the shield is NOT a warrantable repair. The information shown is a suggested repair guide only. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-018B > Feb > 07 > A/T - Cannot Shift After Driving in Ice/Snow > Page 6938 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shift Cable: > 08-08-63-003 > Nov > 08 > Body - Replacement Fender Hood Hinge Hole Too Large Hood Hinge: All Technical Service Bulletins Body - Replacement Fender Hood Hinge Hole Too Large INFORMATION Bulletin No.: 08-08-63-003 Date: November 26, 2008 Subject: Hood Hinge Pivot Hole Too Large On Some Replacement Fenders Models: 1999-2007 Chevrolet Silverado Classic 2001-2006 Chevrolet Avalanche, Suburban, Tahoe 1999-2007 GMC Sierra Classic 2001-2006 GMC Yukon Models Technicians installing GMSPO service replacement fenders may find that the fender side hood hinge pivot bolt attachment hole is too large (12 mm). The hood hinge pivot bolt attachment hole on some service fenders may be too large (12 mm), causing improper retention of the pivot bolt. To correct this condition, add a M8 X 32 mm O.D. X 2 mm thick washer between the hinge halves on the inboard side of the fender side hood hinge. This will provide the proper surface for the shoulder of the pivot bolt to contact as it is tightened. Refer to the illustration above. Parts Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E Shift Cable: Adjustments Automatic Transmission - 4L80-E/4L85-E Automatic Transmission Range Selector Cable Adjustment 1. Ensure that the steering column shift lever is in the park (P) position. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Grasp the shift cable shifter end (1) in the left hand and the shift cable transmission end (2) in the right hand. 5. Align the outside diameter of the transmission end (2) with the inside diameter of the shifter end (1). 6. Push the end of the transmission cable (3) inside the shifter end until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 6951 7. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 8. Pull the white cover (5) on the shifter end (1) back. 9. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). 10. Release the white cover (1). 11. Verify the white cover (1) conceals the natural colored lock (2). 12. If the white cover (1) does not conceal the natural colored lock (2), the shift cable must be re-adjusted. 13. Lower the vehicle. 14. Test the transmission for proper shift operation. 15. If all of the gear positions cannot be achieved, the shift cable must be re-adjusted. Cable Re-Adjustment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 6952 1. Place the steering column shift lever back into the park (P) position. 2. Raise the vehicle. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Pull the white cover (1) back to expose the natural colored lock (2). Under the lock (2), insert a flat bladed screwdriver under the lock ramp located at the top of the lock. The lock will pop up, and the transmission end will move slightly away from the shifter end. 5. Push the end of the transmission end (3) inside the shifter end (1) until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 6953 6. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 7. Pull the white cover (5) on the shifter end (1) back. 8. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). 9. Release the white cover (1). 10. Verify the white cover (1) conceals the natural colored lock (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 6954 Shift Cable: Adjustments Automatic Transmission - Allison Range Selector Cable Adjustment Automatic Transmission Range Selector Cable Adjustment 1. Ensure that the steering column shift lever is in the park (P) position. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Grasp the shift cable shifter end (1) in the left hand and the shift cable transmission end (2) in the right hand. 5. Align the outside diameter of the transmission end (2) with the inside diameter of the shifter end (1). 6. Push the end of the transmission cable (3) inside the shifter end until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 6955 7. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 8. Pull the white cover (5) on the shifter end (1) back. 9. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). 10. Release the white cover (1). 11. Verify the white cover (1) conceals the natural colored lock (2). 12. If the white cover (1) does not conceal the natural colored lock (2), the shift cable must be re-adjusted. 13. Lower the vehicle. 14. Test the transmission for proper shift operation. 15. If all of the gear positions cannot be achieved, the shift cable must be re-adjusted. Cable Re-Adjustment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 6956 1. Place the steering column shift lever back into the park (P) position. 2. Raise the vehicle. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Pull the white cover (1) back to expose the natural colored lock (2). Under the lock (2), insert a flat bladed screwdriver under the lock ramp located at the top of the lock. The lock will pop up, and the transmission end will move slightly away from the shifter end. 5. Push the end of the transmission end (3) inside the shifter end (1) until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 6957 6. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 7. Pull the white cover (5) on the shifter end (1) back. 8. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). 9. Release the white cover (1). 10. Verify the white cover (1) conceals the natural colored lock (2). Shift Cable Adjustment Shift Cable Adjustment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 6958 1. Ensure that the steering column shift lever is in the park (P) position. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Grasp the shift cable shifter end (1) in the left hand and the shift cable transmission end (2) in the right hand. 5. Align the outside diameter of the transmission end (2) with the inside diameter of the shifter end (1). 6. Push the end of the transmission cable (3) inside the shifter end until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 6959 7. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 8. Pull the white cover (5) on the shifter end (1) back. 9. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). 10. Release the white cover (1). 11. Verify the white cover (1) conceals the natural colored lock (2). 12. If the white cover (1) does not conceal the natural colored lock (2), the shift cable must be re-adjusted. 13. Lower the vehicle. 14. Test the transmission for proper shift operation. 15. If all of the gear positions cannot be achieved, the shift cable must be re-adjusted. Cable Re-Adjustment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 6960 1. Place the steering column shift lever back into the park (P) position. 2. Raise the vehicle. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Pull the white cover (1) back to expose the natural colored lock (2). Under the lock (2), insert a flat bladed screwdriver under the lock ramp located at the top of the lock. The lock will pop up, and the transmission end will move slightly away from the shifter end. 5. Push the end of the transmission end (3) inside the shifter end (1) until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 6961 6. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 7. Pull the white cover (5) on the shifter end (1) back. 8. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). 9. Release the white cover (1). 10. Verify the white cover (1) conceals the natural colored lock (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E Shift Cable: Service and Repair Automatic Transmission - 4L80-E/4L85-E Range Selector Cable Replacement Automatic Transmission Range Selector Cable Replacement Removal Procedure 1. Position the steering column shift lever to the park position. 2. Remove the instrument panel knee bolster. 3. Remove the driver's seat. 4. Pull back the carpet and insulation around the driver's area. 5. Remove the retainer securing the cable to the steering column. 6. Remove the cable end from the steering column ball stud. 7. Depress the tangs and remove the cable from the steering column bracket. 8. Remove the bolt securing the cable support to the brace. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6964 9. Important: Avoid unnecessary twisting/bending of the range selector cable when removing the cable from the support. Remove the range selector cable from the support. 10. Remove the cable grommet from the floor panel. 11. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 12. Remove the clips on the cable from the floor panel reinforcement. 13. Ensure the transmission manual shaft is positioned in mechanical park. 14. Remove the retainer that secures the cable to the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6965 15. Remove the cable clip on the transfer case, if equipped. 16. Remove the range selector cable end (2) from the transmission range selector lever ball stud (1). 17. Depress the tangs and remove the cable from the bracket. 18. Lower the vehicle and ensure that the steering column shift lever is still in the park position. Installation Procedure 1. Ensure that the transmission manual shaft lever is in the mechanical park position. 2. Align and install the cable to the bracket. 3. Install the range selector cable end (2) to the transmission range selector lever ball stud (1). 4. Install the cable clip on the transfer case, if equipped. 5. Install the retainer that secures the cable to the bracket. 6. Install the clips on the cable to the floor panel reinforcement. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6966 7. Lower the vehicle. 8. Install the cable grommet to the floor panel. 9. Important: Avoid unnecessary twisting/bending of the range selector cable when installing the cable to the support. Install the range selector cable to the support. 10. Notice: Refer to Fastener Notice in Service Precautions. Install the bolt securing the cable support to the brace. ^ Tighten the bolt to 10 Nm (89 inch lbs.). 11. Install the cable to the steering column bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6967 12. Ensure the tangs fully seat (snap) into the steering column bracket. 13. Install the cable end to the steering column ball stud. 14. Install the retainer securing the cable to the steering column. 15. Position the carpet and insulation around the driver's area. 16. Install the driver's seat. 17. Install the instrument panel knee bolster. 18. Test the transmission for proper shift operation. 19. If all of the gear positions cannot be achieved, adjust the cable. Range Selector Cable Bracket Replacement Automatic Transmission Range Selector Cable Bracket Replacement Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Disconnect the transmission range selector cable from the shift lever and the bracket (2). 5. Remove the bolts (1) securing the transmission range selector cable bracket (2) to the transmission. 6. Remove the transmission range selector cable bracket from the vehicle. Installation Procedure 1. Install the transmission range selector cable bracket to the vehicle. 2. Notice: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6968 Refer to Fastener Notice in Service Precautions. Install the transmission range selector cable bracket bolts (1). ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 3. Install the transmission range selector cable to the bracket (2) and the lever. 4. Lower the vehicle. 5. Check the vehicle for proper operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6969 Shift Cable: Service and Repair Automatic Transmission - Allison Automatic Transmission Range Selector Cable Replacement Removal Procedure 1. Position the shift lever into the park (P) position. 2. Remove the instrument panel knee bolster. 3. Remove the retainer securing the cable to the steering column. 4. Remove the cable end from the steering column ball stud. 5. Depress the tangs and remove the cable from the steering column bracket. 6. Remove the bolt securing the cable support to the brace. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6970 7. Important: Avoid unnecessary twisting/bending of the selector cable when removing the cable from the support. Remove the range selector cable from the support. 8. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 9. Ensure the transmission manual shaft is positioned in mechanical park. 10. Remove the range selector cable end (2) from the transmission range selector lever ball stud (1). 11. Remove the retainer securing the cable to the bracket. 12. Depress the tangs and remove the cable from the transmission bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6971 13. Remove the cable clips from the floor panel reinforcement. 14. Remove the cable clips (2) from the transfer case, if equipped. 15. Lower the vehicle. 16. Pull back the carpet and insulation around the driver's area. 17. Remove the cable grommet from the floor panel. 18. Remove the cable from the hole in the floor panel. Installation Procedure 1. Instal the cable to the hole in the floor panel. 2. Install the cable grommet to the floor panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6972 3. Position the carpet and insulation around the driver's area. 4. Raise the vehicle. 5. Install the cable clips (2) to the transfer case, if equipped. 6. Install the cable clips to the floor panel reinforcement. 7. Ensure the transmission manual shaft is positioned in mechanical park. 8. Install the cable to the transmission bracket. 9. Install the retainer securing the cable to the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6973 10. Install the range selector cable end (2) to the transmission range selector lever ball stud (1). 11. Lower the vehicle. 12. Important: Avoid unnecessary twisting/bending of the range selector cable when removing the cable from the support. Install the range selector cable to the support. 13. Notice: Refer to Fastener Notice in Service Precautions. Install the bolt securing the cable support to the brace. ^ Tighten the bolt to 10 Nm (89 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 6974 14. Install the cable to the steering column bracket. 15. Install the cable end to the steering column ball stud. 16. Install the retainer securing the cable to the steering column. 17. Install the instrument panel knee bolster. 18. If all of the gear positions cannot be achieved, adjust the cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: Customer Interest A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 6983 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 6984 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: All Technical Service Bulletins A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 6990 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 6991 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information Torque Converter: Technical Service Bulletins A/T - Torque Converter Replacement Information INFORMATION Bulletin No.: 01-07-30-010C Date: May 12, 2008 Subject: Automatic Transmission/Transaxle Torque Converter Replacement Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75) 2009 and Prior Saab 9-7X with ALL Automatic Transmissions and Transaxles Supercede: This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin Number 01-07-30-010B (Section 07 - Transmission/Transaxle). The purpose of this bulletin is to help technicians determine when a torque converter should be replaced. Below is a list of general guidelines to follow. The converter should NOT be replaced if the following apply: ^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition (i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical concern within the torque converter. ^ The fluid has an odor or is discolored but no evidence of metal contamination. ^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is not harmful to the torque converter. ^ The vehicle has been exposed to high mileage. ^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter (RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither the converter nor the front pump assembly should be replaced. The torque converter should be replaced under any of the following conditions: ^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the converter bushing and/or internal 0-ring may be damaged. ^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support and bearing or metal chips/debris in the converter. ^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines. ^ External leaks in the hub weld area lug weld or closure weld. ^ Converter pilot is broken damaged or fits poorly into the crankshaft. ^ The converter hub is scored or damaged. ^ The transmission oil is contaminated with engine coolant engine oil or water. ^ If excessive end play is found after measuring the converter for proper end play (refer to Service Manual). ^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit are worn or damaged. This indicates that the material came from the converter. ^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by following Converter Vibration Procedures. ^ Blue converter or dark circular ring between lugs. This condition will also require a complete cleaning of the cooler and a check for adequate flow Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information > Page 6996 through the cooler. ^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at idle. The noise is gone in Neutral and Park. ^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY). Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 6997 Torque Converter: Service and Repair Torque Converter Replacement ^ Tools Required J 21366 Converter Holding Strap - J 46409Torque Converter Lifting Handles - J 44723 Transmission/Stand Adaptor Plate Removal Procedure 1. Remove the transmission from the vehicle. 2. Install J 21366 to restrain the torque converter. 3. Install J 44723. 4. Position the transmission vertically with the torque converter end up. 5. Remove J 21366 torque converter retaining bracket. 6. Important: The distance from the torque converter mounting lugs to the transmission mounting face is an important measurement. It is required to check correct reassembly of the torque converter. Measure from the mounting lugs to the transmission mounting face. 7. Install J 46409 Torque Converter Lifting Handles 180 degrees apart into two lugs on the front of the torque converter. 8. Caution: Avoid personal injury or property damage when removing or installing the torque converter by seeking an assistant to help lift the torque converter. Lift the torque converter free of the transmission and place it on the work table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 6998 9. Remove the lifting handles. Installation Procedure 1. Lubricate the converter pump hub OD and the torque converter seal with clean transmission fluid. 2. Install J 46409 Torque Converter Lifting Handles 180 degrees apart into two lugs on the front of the torque converter. 3. Caution: Avoid personal injury or property damage when removing or installing the torque converter by seeking an assistant to help lift the torque converter. Lift the torque converter and place it in the transmission. 4. Spin the torque converter to engage the turbine shaft splines in the torque converter hub, the ground sleeve splines in the stator race and to engage the drive flats on the converter pump hub with the oil pump drive gear. 5. The torque converter is correctly installed when the distance from the lugs to the mounting face is the same as when measured before removing the torque converter. 6. Install the J 21366 Converter Holding Strap. 7. Reinstall the transmission into the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting Torque Converter Check Valve: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 7003 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Service and Repair Torque Converter Clutch: Service and Repair Torque Converter Clutch (TCC) Valve and Spring Replacement Removal Procedure 1. Remove the transmission filter. Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. 2. Remove the valve bore plug retainer ring (1). 3. Remove the following parts: ^ The valve bore plug ^ The TCC valve ^ The TCC valve spring Installation Procedure 1. Install the following parts: ^ The TCC valve spring ^ The TCC valve ^ The valve bore plug Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Service and Repair > Page 7007 2. Install the valve bore plug retainer ring (1). 3. Install the transmission filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 7012 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 7013 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Remove the transmission filter. 2. Disconnect the transmission harness 20-way connector (1) from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. 3. Important: Removal of the valve body is not necessary for the following procedure. Remove the 1-2 accumulator. Do not remove the spacer plate. 4. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ Torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 5. Remove the TCC PWM solenoid retainer. 6. Remove the TCC PWM solenoid in order to access one of the TCC solenoid bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 7014 7. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 8. Remove the pressure control solenoid (377). 9. Remove the TCC solenoid bolts and the valve body bolts which retain the internal wiring harness. 10. Using J 28458 , release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the four tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 7015 12. Inspect the TCC solenoid and wiring harness for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid bolts. ^ Tighten the control valve body bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid bolts to 11 Nm (97 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 7016 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 7017 ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector (1) to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush Transmission Cooler: Technical Service Bulletins A/T - Fluid Oil Cooler Flush INFORMATION Bulletin No.: 02-07-30-052G Date: March 02, 2011 Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow(R) Models: 2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle). Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J 35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled through the transmission oil cooling system. High-pressure air is automatically injected into the fluid stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris. In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can be used for verification of flow test results. Current essential cooler line adapters are used to connect the J 45096 to the automatic transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo). The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership personnel with a barbed hose connector and rubber hose obtained locally. The Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the Vibe's/Wave's/Aveo's transmission fluid. Notice Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure. The required minimum ATF oil flow rate reading is directly related to the supply oil temperature. Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of the ATF in the supply vessel. Helpful Hints for Maintaining the Temperature at or above 18°C (65°F) Important - The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It is recommended to store the J 45096 in an area of the dealership where the room temperature remains at or above 18°C (65°F) when not in use. - Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the supply reservoir. Inserting a heater will damage the check valve and the subsequent repair expense would be the dealer's responsibility. - A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110 volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a thermostat to hold a constant temperature. Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room where the temperature is maintained at or above 18°C (65°F). Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J 45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the machine on Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 7022 each repair. With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the reservoir. Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the reservoir to the rays of the warm sun. Flush / Flow Test Procedure Important All labor operations that include removal of the transmission from the vehicle and require the transmission oil pan or transmission side cover to be removed include labor time to flush the transmission oil cooler system. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate procedure. Important The J 45096 can be used to flush the transmission oil cooler system on an Allison equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure. Machine Displays After completion of the flush and flow test, the following information is to be recorded on the repair order. This information is displayed on the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine when the dial is in the code position. - Tested flow rate (displayed in Gallons Per Minute (GPM) - Temperature (displayed is degrees Fahrenheit) - Cycle number (a number) - Seven digit Alpha/Numeric flow code (i.e. A10DFB2) Warranty Information Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts) of DEXRON(R)VI transmission fluid. The amount Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 7023 of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be shown in the Parts Section of the warranty claim document. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card, entered in the warranty claim labor operation Flush Code additional field (when available) and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 7024 Transmission Cooler: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 7025 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 7026 Transmission Cooler: Technical Service Bulletins A/T - Allison Cooler Line Adapter Tool/Flushing Bulletin No.: 05-07-30-002 Date: January 25, 2005 INFORMATION Subject: New Essential Tool J 45096-23 Automatic Transmission Oil Cooler Line Adapter for Allison Transmission Models: 2003-2005 Chevrolet Silverado 2003-2005 GMC Sierra with Allison Automatic Transmission (RPO M74) A revised transmission oil cooler line went into production during the 2003 model year. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 7027 A new transmission oil cooler line adapter tool , J 45096-23, is being released for use with the new oil cooler line. The outside diameter of the crimp on the end of the oil cooler line is slightly smaller than the previous transmission oil cooler line. Under certain conditions, the current tool, J 44835-1, could leak or come off if used on the improved design transmission oil cooler line. Refer to Corporate Bulletin Number 02-07-30-052C or newer for the proper transmission oil cooler flushing and flow test procedures. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E Transmission Cooler: Service and Repair Automatic Transmission - 4L80-E/4L85-E Transmission Oil Cooler Line Quick Connect Fitting Transmission Oil Cooler Line Quick Connect Fitting Removal Procedure 1. Important: Perform the following procedure when removing the retaining rings and cooler lines from the quick connect fittings located on the radiator and/or the transmission. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm (2 inch). 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. 3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring. 5. Pull the cooler line straight out from the quick connect fitting. Installation Procedure 1. Important: ^ Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion. ^ Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. Install new retaining rings. ^ Ensure the following procedures are performed when installing the new retaining rings onto the fittings. Install a new retaining ring into the quick connect fitting using the following procedure: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7030 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. 3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. 4. Do not install the new retaining ring onto the fitting by pushing the retaining ring. 5. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7031 6. Install the cooler line into the quick connect fitting. 7. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. 8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 9. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. 10. Important: Do not manually depress the retaining clip when installing the plastic cap. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. 11. Ensure that the plastic cap is fully seated against the fitting. 12. Ensure that no gap is present between the cap and the fitting. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7032 13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. 14. A hidden yellow identification band indicates proper joint seating. 15. Fill the transmission to the proper level with DEXRON® III transmission fluid. Transmission Fluid Auxiliary Cooler Replacement Transmission Fluid Auxiliary Cooler Replacement Removal Procedure 1. Remove the grille assembly. 2. Remove the transmission fluid cooler hoses from the auxiliary cooler. 3. Remove the auxiliary oil cooler bolts (1). 4. Remove the auxiliary oil cooler push pins (2) 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7033 1. Install the auxiliary oil cooler to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the bolts (1) to the radiator brace. ^ Tighten the bolts to 12 Nm (106 inch lbs.). 3. Install the push pins (2) to the radiator brace. 4. Connect the transmission oil cooler lines to the auxiliary cooler. 5. Install the grille assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7034 Transmission Cooler: Service and Repair Automatic Transmission - Allison Automatic Transmission Oil Cooler Fitting Replacement Automatic Transmission Oil Cooler Fitting Replacement Removal Procedure 1. Disconnect the hose from the hydraulic connector assembly being replaced. 2. Remove the hydraulic connector assembly (1) and (2). Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install a new hydraulic connector assembly (1) and (2). ^ Tighten to 25 Nm (18 ft. lbs.). 2. Connect the hose to the hydraulic connectors. Transmission Fluid Auxiliary Cooler Replacement Transmission Fluid Auxiliary Cooler Replacement Removal Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7035 1. Remove the front grill assembly. 2. Place a drain pan under the vehicle. 3. Disconnect the transmission oil cooler lines from the auxiliary cooler. 4. Remove the auxiliary oil cooler bolts (1) and push pins (2). 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure 1. Install the auxiliary oil cooler to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the bolts (1) and the push pins (2) that retain the auxiliary oil cooler to the radiator brace. ^ Tighten the bolts to 12 Nm (106 inch lbs.). 3. Connect the transmission oil cooler lines to the auxiliary cooler. 4. Install the front grill assembly. 5. Check and add transmission fluid as necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch: Testing and Inspection 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 7040 Steps 1-9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 7041 Tow/Haul Switch: Testing and Inspection 4L80-E/4L85-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between up shifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit checks are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 7042 Steps 1-9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E Transmission Mount: Service and Repair Automatic Transmission - 4L80-E/4L85-E Transmission Mount Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Remove the transmission mount to the transmission support retaining nut or nuts. 4. Raise the transmission to take the weight off of the mount. 5. Remove the transmission mount to the transmission or transfer case adapter mounting bolts (1). 6. Raise the transmission just enough to remove the transmission mount. 7. Remove the transmission mount from the vehicle. Installation Procedure 1. Install the transmission mount to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the transmission mount to the transmission or transfer case adapter mounting bolts (1). ^ Tighten the bolts to 50 Nm (37 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7047 3. Lower the transmission. 4. Install the transmission mount to the transmission support retaining nut or nuts. ^ Tighten the nut or nuts to 40 Nm (30 ft. lbs.). 5. Remove the transmission jack. 6. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7048 Transmission Mount: Service and Repair Automatic Transmission - Allison Transmission Mount Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Remove the transmission mount to the transmission support retaining nut or nuts. 4. Raise the transmission to take the weight off of the mount. 5. Remove the transmission mount to the transmission or transfer case adapter mounting bolts (1). 6. Raise the transmission just enough to remove the transmission mount. 7. Remove the transmission mount from the vehicle. Installation Procedure 1. Install the transmission mount to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the transmission mount to the transmission or transfer case adapter mounting bolts (1). ^ Tighten the bolts to 50 Nm (37 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7049 3. Lower the transmission. 4. Install the transmission mount to the transmission support retaining nut or nuts. ^ Tighten the nut or nuts to 40 Nm (30 ft. lbs.). 5. Remove the transmission jack. 6. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start Transmission Position Switch/Sensor: Customer Interest A/T - Slow/No Gear Engagement/Engine No Start Bulletin No.: 02-07-30-011C Date: June 21, 2004 TECHNICAL Subject: Slow or No Engagement of Automatic Transmission, No Start, Blank PRNDL Display, Flashing PRNDL, DTC P0708, P0872, P0847, P0875, P1711, P1713 or U1000 Set (Diagnose Condition, Repair According to Procedure) Models: 2001-2004 Chevrolet Silverado 2001-2004 GMC Sierra with Allison(R) LCT1000 Automatic Transmission (RPO M74) and 6.6L Duramax(TM) Diesel Engine (RPO LB7) or 8.1L Gas Engine (RPO L18) Supercede: This bulletin is being revised to add model years and additional model information and add graphics. Please discard Corporate Bulletin Number 02-07-30-011B (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions. ^ The PRNDL display is flashing. ^ The engine will not start. ^ The "Service Engine Soon" Indicator lamp is illuminated. ^ The transmission does not shift properly. ^ The vehicle will not move, transmission will not engage. Cause Moisture contamination within the Park Neutral Position (PNP) Switch may cause this condition. This is sometimes referred to as the Neutral Start Back-up (NSBU) Switch. On a left turn, water spray from the left front tire is directed directly at this switch. Proper installation of the "Front Shield" and "Rear Shield" are essential for proper repairs. Technician Diagnosis This bulletin ONLY applies to vehicles equipped with a two connector PNP switch as shown above. A complete and through diagnosis must be performed by a qualified electrical technician to determine the cause and avoid needless replacement of good components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 7058 Important: The Transmission Control Module (TCM) and or the Pressure Switch Manifold (PSM) should NOT be replaced unless properly diagnosed. They are probably not the cause of the concern. It is often assumed the module is the cause of the concern when, in fact, it is another component or the wiring between the components that causes the concern. Important: Remember, everything starts with a properly operating Neutral Start Back Up (NSBU) switch. The NSBU switch has been incorporated into what is now called the Park Neutral Position (PNP) switch. If the PNP switch does not provide the proper voltage signal to the module indicating the transmission is in either Park or Neutral, the module will not allow the starter operation. After the engine is started, and the shift lever is moved to either Reverse or one of the drive positions, the range selected portion of the PNP switch portion provides a voltage input to the module as to what range the driver has manually selected for transmission operation. The module then controls pressures, shift points and other transmission functions based on the voltage input received from the range portion of the PNP switch. The technician may find one or more of the following conditions. The list of these conditions does not imply any type of frequency or order. They are random events and may occur in any order. ^ DTC P0708, Neutral start/backup (PNP or NSBU) switch ^ DTC P0847, Pressure Switch Manifold (PSM) ^ DTC P0872, Pressure Switch Manifold (PSM) ^ DTC P0875, Pressure Switch Manifold (PSM) ^ DTC P1711, Pressure Switch Manifold (PSM) ^ DTC P1713, Pressure Switch Manifold (PSM) ^ DTC U1000, Serial Data Communications ^ Blank PRNDL Display ^ Flashing PRNDL Display ^ Slow or No Engagement of Automatic Transmission Blank PRNDL Display A blank PRNDL display may indicate a condition with the PNP switch and/or one or more of the four signal circuits from the PNP to the TCM. 1. Pin A, Circuit 771 (BLK/WHT) 2. Pin B, Circuit 773 (GRA) 3. Pin C, Circuit 776 (WHT) 4. Pin D, Circuit 772 (YEL) Or, a blank PRNDL display may also occur if an out of line condition exists with the Serial Data Circuit (CKT 2470, yellow wire) from the TCM to Splice Pack 205. Diagnostic Tip 1. Connect the Tech 2(R) to the vehicle. 2. Power up the Tech 2(R). 3. Does the Tech 2(R) communicate with the TCM? If not, inspect the serial data circuit, CKT 2470 (Yellow wire), between the TCM and Splice Pack 205. Specifically inspect connector C106, a five terminal connector located below the left side underhood bussed electrical center, directly beneath the red battery cable terminal connection. Perform a mating terminal pull test on all of the terminals in this connector. Repair as required. 4. Observe the Gear Selected screen on the scan tool. The following values should be shown on the Tech 2(R) display and the vehicle's instrument panel cluster (if equipped with the I/P display). ^ "8" (shifter should be in the Park position) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 7059 ^ "7" (shifter should be in the Reverse position) ^ "5" (shifter should be in the Drive position) ^ "3" (shifter should be in the Third gear position) ^ "2" (shifter should be in the Second gear position) ^ "1" (shifter should be in the First gear position) ^ "0" (shifter should be in the Neutral Position) If the Gear Selected display does not match the shifter position in the vehicle, diagnose using one of the following methods. ^ Obtain a new PNP switch kit, P/N 29540479, from the Parts Department. ^ 0.1. Disconnect the wiring connector from the original transmission mounted PNP switch. ^ 0.2. Connect the new switch to the wiring connector. ^ 0.3. Return to Step # 4 above and observe the display as you rotate the switch. If all positions indicate properly, refer to the Correction section below. ^ Use the DTC P0708 diagnostic chart in Service Information (SI) under Transmission/Transaxle/Automatic Transmission - Allison. Reference SI Document ID # 769549 for the wiring schematic for this symptom. The PNP switch, as referenced in SI, is known as the NSBU switch in the Parts information. It is now serviced with a Park Neutral Position Switch Kit, P/N 29540479. Flashing PRNDL Display A flashing PRNDL display may be the result of incorrect sensor inputs or transmission abuse protection modes being received by the TCM. The following are some of these conditions: ^ The transfer case is/was in Neutral. ^ The transfer case is/was shifted into Neutral when the vehicle is moving. ^ A decrease of the input turbine speed was not detected when the gear selector was moved into any gear. ^ A low transmission fluid level. ^ A misadjusted PNP/NSBU switch. ^ Turbine input speed or output speed sensor failure. ^ Failures of the shift solenoids to route the transmission oil to the proper clutch assemblies within the transmission. ^ Failures of the transmission clutch packs (C1 or C5 for first gear, C3 or C5 for Reverse). ^ Failure to detect proper line pressures when a gear range is selected, which may be the result of normal maintenance such as a transmission fluid change having been completed, or the transmission pan was removed for a filter replacement or other type service. Transmission abuse protection modes are encountered when a customer performs one of the following types of maneuvers: ^ Shifting from Neutral to Drive/Reverse when the engine RPM is greater than 1400 RPM. ^ Shifting from Drive to Reverse when the throttle position (TPS) is greater than 25%, such as rocking the vehicle when stuck in an attempt to free the vehicle. ^ When the transmission output speed is greater than 300 RPM from attempted changes in direction such as Reverse to Drive, Drive to Reverse or Neutral to Reverse shifts. When the TCM encounters any one of the above conditions, the TCM will flash the PRNDL and default the transmission to Neutral. A flashing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 7060 PRNDL indicates something is/was incorrect. The transmission may need the attention of a qualified service technician. Correction 1. Disconnect the wiring harness from the PNP switch. 2. Disconnect the shift linkage/cable from the shift lever at the transmission. 3. With a wrench keeping the shift lever from rotating, remove the nut from the end of the selector shaft. 4. Use a file to remove any burrs or raised metal where the selector lever was seated against the shoulder of the selector shaft. Important: If the old PNP switch will not slide from the selector shaft without the effort, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 5. Remove the two bolts that attach the PNP switch and remove the switch by sliding it outward over the selector shaft. 6. Make sure the selector shaft is in the N (neutral) position (using a wrench on the selector shaft flats, rotate the shaft to its furthest clockwise position and then rotate counterclockwise two detents). Important: If the new PNP switch will not slide onto the selector shaft easily, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 7. Slide the new PNP switch over the selector shaft with the neutral assurance bracket 920 facing outward and maintaining the correct PNP switch orientation to the selector shaft. Install and hand tighten the two PNP switch attaching bolts so that the PNP switch and bracket may be rotated within the adjusting slots with some effort. 8. While holding the neutral assurance bracket in engagement with the PNP switch, tighten the two bolts that attach the PNP switch to the transmission case. Tighten Tighten the bolts to 27 N.m (20 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 7061 9. Remove and discard the neutral assurance bracket. Important: Installation of the front shield and rear shields are important. Without proper installation of the shield, a return repair is probable. Follow all directions as listed on the installation instructions sheet included in the Switch kit, P/N 29540479. 10. Fit the new shield onto the PNP switch so that it fits securely against the switch. Make sure this is done before reinstalling the shift lever. 11. Reinstall the shift lever. With a wrench keeping the shift lever from rotating, install the nut on the end of the selector shaft. Tighten. Tighten the nut to 24 N.m (18 lb ft). 12. Connect the wiring harness connectors to the PNP switch. 13. Attach the selector cable to the lever. Check and adjust if needed. 14. Go back to step 4 of the Diagnostics and insure the Tech 2 readings match the shift lever positions. Important: Clear all DTCs before returning the vehicle to the customer. 15. Return the vehicle to the customer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 7062 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Slow/No Gear Engagement/Engine No Start Bulletin No.: 02-07-30-011C Date: June 21, 2004 TECHNICAL Subject: Slow or No Engagement of Automatic Transmission, No Start, Blank PRNDL Display, Flashing PRNDL, DTC P0708, P0872, P0847, P0875, P1711, P1713 or U1000 Set (Diagnose Condition, Repair According to Procedure) Models: 2001-2004 Chevrolet Silverado 2001-2004 GMC Sierra with Allison(R) LCT1000 Automatic Transmission (RPO M74) and 6.6L Duramax(TM) Diesel Engine (RPO LB7) or 8.1L Gas Engine (RPO L18) Supercede: This bulletin is being revised to add model years and additional model information and add graphics. Please discard Corporate Bulletin Number 02-07-30-011B (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions. ^ The PRNDL display is flashing. ^ The engine will not start. ^ The "Service Engine Soon" Indicator lamp is illuminated. ^ The transmission does not shift properly. ^ The vehicle will not move, transmission will not engage. Cause Moisture contamination within the Park Neutral Position (PNP) Switch may cause this condition. This is sometimes referred to as the Neutral Start Back-up (NSBU) Switch. On a left turn, water spray from the left front tire is directed directly at this switch. Proper installation of the "Front Shield" and "Rear Shield" are essential for proper repairs. Technician Diagnosis This bulletin ONLY applies to vehicles equipped with a two connector PNP switch as shown above. A complete and through diagnosis must be performed by a qualified electrical technician to determine the cause and avoid needless replacement of good components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 7068 Important: The Transmission Control Module (TCM) and or the Pressure Switch Manifold (PSM) should NOT be replaced unless properly diagnosed. They are probably not the cause of the concern. It is often assumed the module is the cause of the concern when, in fact, it is another component or the wiring between the components that causes the concern. Important: Remember, everything starts with a properly operating Neutral Start Back Up (NSBU) switch. The NSBU switch has been incorporated into what is now called the Park Neutral Position (PNP) switch. If the PNP switch does not provide the proper voltage signal to the module indicating the transmission is in either Park or Neutral, the module will not allow the starter operation. After the engine is started, and the shift lever is moved to either Reverse or one of the drive positions, the range selected portion of the PNP switch portion provides a voltage input to the module as to what range the driver has manually selected for transmission operation. The module then controls pressures, shift points and other transmission functions based on the voltage input received from the range portion of the PNP switch. The technician may find one or more of the following conditions. The list of these conditions does not imply any type of frequency or order. They are random events and may occur in any order. ^ DTC P0708, Neutral start/backup (PNP or NSBU) switch ^ DTC P0847, Pressure Switch Manifold (PSM) ^ DTC P0872, Pressure Switch Manifold (PSM) ^ DTC P0875, Pressure Switch Manifold (PSM) ^ DTC P1711, Pressure Switch Manifold (PSM) ^ DTC P1713, Pressure Switch Manifold (PSM) ^ DTC U1000, Serial Data Communications ^ Blank PRNDL Display ^ Flashing PRNDL Display ^ Slow or No Engagement of Automatic Transmission Blank PRNDL Display A blank PRNDL display may indicate a condition with the PNP switch and/or one or more of the four signal circuits from the PNP to the TCM. 1. Pin A, Circuit 771 (BLK/WHT) 2. Pin B, Circuit 773 (GRA) 3. Pin C, Circuit 776 (WHT) 4. Pin D, Circuit 772 (YEL) Or, a blank PRNDL display may also occur if an out of line condition exists with the Serial Data Circuit (CKT 2470, yellow wire) from the TCM to Splice Pack 205. Diagnostic Tip 1. Connect the Tech 2(R) to the vehicle. 2. Power up the Tech 2(R). 3. Does the Tech 2(R) communicate with the TCM? If not, inspect the serial data circuit, CKT 2470 (Yellow wire), between the TCM and Splice Pack 205. Specifically inspect connector C106, a five terminal connector located below the left side underhood bussed electrical center, directly beneath the red battery cable terminal connection. Perform a mating terminal pull test on all of the terminals in this connector. Repair as required. 4. Observe the Gear Selected screen on the scan tool. The following values should be shown on the Tech 2(R) display and the vehicle's instrument panel cluster (if equipped with the I/P display). ^ "8" (shifter should be in the Park position) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 7069 ^ "7" (shifter should be in the Reverse position) ^ "5" (shifter should be in the Drive position) ^ "3" (shifter should be in the Third gear position) ^ "2" (shifter should be in the Second gear position) ^ "1" (shifter should be in the First gear position) ^ "0" (shifter should be in the Neutral Position) If the Gear Selected display does not match the shifter position in the vehicle, diagnose using one of the following methods. ^ Obtain a new PNP switch kit, P/N 29540479, from the Parts Department. ^ 0.1. Disconnect the wiring connector from the original transmission mounted PNP switch. ^ 0.2. Connect the new switch to the wiring connector. ^ 0.3. Return to Step # 4 above and observe the display as you rotate the switch. If all positions indicate properly, refer to the Correction section below. ^ Use the DTC P0708 diagnostic chart in Service Information (SI) under Transmission/Transaxle/Automatic Transmission - Allison. Reference SI Document ID # 769549 for the wiring schematic for this symptom. The PNP switch, as referenced in SI, is known as the NSBU switch in the Parts information. It is now serviced with a Park Neutral Position Switch Kit, P/N 29540479. Flashing PRNDL Display A flashing PRNDL display may be the result of incorrect sensor inputs or transmission abuse protection modes being received by the TCM. The following are some of these conditions: ^ The transfer case is/was in Neutral. ^ The transfer case is/was shifted into Neutral when the vehicle is moving. ^ A decrease of the input turbine speed was not detected when the gear selector was moved into any gear. ^ A low transmission fluid level. ^ A misadjusted PNP/NSBU switch. ^ Turbine input speed or output speed sensor failure. ^ Failures of the shift solenoids to route the transmission oil to the proper clutch assemblies within the transmission. ^ Failures of the transmission clutch packs (C1 or C5 for first gear, C3 or C5 for Reverse). ^ Failure to detect proper line pressures when a gear range is selected, which may be the result of normal maintenance such as a transmission fluid change having been completed, or the transmission pan was removed for a filter replacement or other type service. Transmission abuse protection modes are encountered when a customer performs one of the following types of maneuvers: ^ Shifting from Neutral to Drive/Reverse when the engine RPM is greater than 1400 RPM. ^ Shifting from Drive to Reverse when the throttle position (TPS) is greater than 25%, such as rocking the vehicle when stuck in an attempt to free the vehicle. ^ When the transmission output speed is greater than 300 RPM from attempted changes in direction such as Reverse to Drive, Drive to Reverse or Neutral to Reverse shifts. When the TCM encounters any one of the above conditions, the TCM will flash the PRNDL and default the transmission to Neutral. A flashing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 7070 PRNDL indicates something is/was incorrect. The transmission may need the attention of a qualified service technician. Correction 1. Disconnect the wiring harness from the PNP switch. 2. Disconnect the shift linkage/cable from the shift lever at the transmission. 3. With a wrench keeping the shift lever from rotating, remove the nut from the end of the selector shaft. 4. Use a file to remove any burrs or raised metal where the selector lever was seated against the shoulder of the selector shaft. Important: If the old PNP switch will not slide from the selector shaft without the effort, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 5. Remove the two bolts that attach the PNP switch and remove the switch by sliding it outward over the selector shaft. 6. Make sure the selector shaft is in the N (neutral) position (using a wrench on the selector shaft flats, rotate the shaft to its furthest clockwise position and then rotate counterclockwise two detents). Important: If the new PNP switch will not slide onto the selector shaft easily, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 7. Slide the new PNP switch over the selector shaft with the neutral assurance bracket 920 facing outward and maintaining the correct PNP switch orientation to the selector shaft. Install and hand tighten the two PNP switch attaching bolts so that the PNP switch and bracket may be rotated within the adjusting slots with some effort. 8. While holding the neutral assurance bracket in engagement with the PNP switch, tighten the two bolts that attach the PNP switch to the transmission case. Tighten Tighten the bolts to 27 N.m (20 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 7071 9. Remove and discard the neutral assurance bracket. Important: Installation of the front shield and rear shields are important. Without proper installation of the shield, a return repair is probable. Follow all directions as listed on the installation instructions sheet included in the Switch kit, P/N 29540479. 10. Fit the new shield onto the PNP switch so that it fits securely against the switch. Make sure this is done before reinstalling the shift lever. 11. Reinstall the shift lever. With a wrench keeping the shift lever from rotating, install the nut on the end of the selector shaft. Tighten. Tighten the nut to 24 N.m (18 lb ft). 12. Connect the wiring harness connectors to the PNP switch. 13. Attach the selector cable to the lever. Check and adjust if needed. 14. Go back to step 4 of the Diagnostics and insure the Tech 2 readings match the shift lever positions. Important: Clear all DTCs before returning the vehicle to the customer. 15. Return the vehicle to the customer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 7072 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 04-08-111-002B > Oct > 06 > Body - Dimple In Body Side Molding(s) Lower Side Moulding / Trim: All Technical Service Bulletins Body - Dimple In Body Side Molding(s) Bulletin No.: 04-08-111-002B Date: October 26, 2006 TECHNICAL Subject: Dimple in Body Side Molding (Replace Moldings) Models: 2004 Chevrolet Avalanche without Body Hardware (RPO WBH) 2004 Chevrolet Silverado, Suburban, Tahoe with Body/Side Exterior-Molding-in-Color (RPO B85) Supercede: This bulletin is being revised to change the Warranty and add a revised parts information statement. Please discard Corporate Bulletin Number 04-08-111-002A (Section 08 - Body and Accessories). Condition Some customers may comment on a raised surface or a dimple in the exterior molded-in-color body side door moldings. This condition may be more pronounced in warmer climates. This does not apply to standard colored keyed black body side moldings. Cause Engineering has determined that this condition may be caused by a bar code label on the backside of the molding that dimples the molding. Correction Replace ALL of the exterior body side door moldings. Refer to Molding Replacement-Body Side procedure in SI. Dealer Action Please contact all customers that were told they would be called when a repair became available. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 04-08-111-002B > Oct > 06 > Body - Dimple In Body Side Molding(s) > Page 7078 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 04-08-111-002B > Oct > 06 > Body - Dimple In Body Side Molding(s) > Page 7079 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 04-08-111-002B > Oct > 06 > Body - Dimple In Body Side Molding(s) > Page 7080 The moldings are available in factory colors; however, quantities are limited. When these quantities are exhausted, the moldings will only be available in paint to match only. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 04-08-111-002B > Oct > 06 > Body - Dimple In Body Side Molding(s) > Page 7086 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 04-08-111-002B > Oct > 06 > Body - Dimple In Body Side Molding(s) > Page 7087 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 04-08-111-002B > Oct > 06 > Body - Dimple In Body Side Molding(s) > Page 7088 The moldings are available in factory colors; however, quantities are limited. When these quantities are exhausted, the moldings will only be available in paint to match only. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 7089 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 7090 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 7093 Transmission Position Switch/Sensor: Adjustments Automatic Transmission - Allison Park/Neutral Position Switch Adjustment ^ Tools Required J 41364-A PNP Switch Adjusting Tool Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Make sure the selector shaft is in the N (Neutral) position as follows: ^ Place a wrench on the selector shaft flats and rotate the shaft to its furthest clockwise position. ^ Rotate the selector shaft counter-clockwise two detents. 2. Be sure that J 41364-A (2) is in the proper position on PNP switch (1). 3. While maintaining the correct PNP switch-to-selector-shaft alignment, slide the new PNP switch (5) over the selector shaft (4). 4. Notice: Refer to Component Fastener Tightening Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 7094 While holding J 41364-A in engagement with the PNP switch, install the two bolts (6) so that the PNP switch may be rotated with some effort. ^ Tighten the two bolts (6) to 27 Nm (20 ft. lbs.). 5. Remove J 41364-A. 6. Install splash shield (1), concave side toward PNP switch (3), over selector shaft (2). 7. Notice: Refer to Transmission Selector Shaft Abuse Notice in Service Precautions. Reinstall Shift Lever (2). Install nut (3), by hand, on the end of selector shaft (4). Use a wrench (1) to keep the shift lever from rotating. ^ Tighten nut (3) to 24 Nm (18 ft. lbs.) 8. Reconnect the shift selector linkage/cable to the shift lever (2). 9. Connect the external wiring harness to the PNP switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L80-E/4L85-E Park/Neutral Position Switch Replacement Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7097 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7098 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7099 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Park Lock Pawl and Actuator Replacement Park Lock Pawl and Actuator Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the park/neutral position (PNP) switch. 3. Remove the manual shaft nut and pin. 4. Remove the detent lever and actuator. 5. Remove the parking pawl bracket bolts. 6. Remove the parking pawl return spring. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7100 7. Use the modified screw extractor in order to remove the plug. 8. Remove the parking pawl shaft retainer, shaft and pawl. 9. Important: If the manual shaft binds in the case during removal, file or sand the shaft in the area adjacent to the detent lever. Remove the manual shaft. 10. Remove the manual shaft seal. Installation Procedure 1. Install the pawl shaft. 2. Install the parking pawl. 3. Install the plug using a 8 mm or (5/16 inch) rod with Loctite® or equivalent. 4. Install the retainer. 5. Install the pawl return spring. 6. Install the detent lever to the actuator. 7. Install the actuator over the parking pawl. 8. Install the manual shaft seal. 9. Lubricate the manual shaft with transmission oil and install the manual shaft into the case. 10. Install the nut on the shaft. 11. Install the roll pin. 12. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7101 Install the parking lock bracket bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 13. Install the PNP switch. 14. Install the transmission filter. 15. Fill the transmission to the proper level with Dexron® III transmission fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7102 Transmission Position Switch/Sensor: Service and Repair Automatic Transmission - Allison Park/Neutral Position Switch Replacement PNP Switch Removal Refer to Park/Neutral Position Switch Removal. PNP Switch Install Refer to Park/Neutral Position Switch Installation. 7. Notice: Refer to Transmission Selector Shaft Abuse Notice in Service Precautions. Reinstall shift lever (2). Install nut (3), by hand, on the end of selector shaft (4). Use a wrench (1) to keep the shift lever from rotating. ^ Tighten nut (3) to 24 Nm (18 ft. lbs.). 8. Reconnect the shift selector linkage/cable to the shift lever (2). 9. Connect the external wiring harness to the PNP switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Service and Repair Transmission Pressure Test Port: Service and Repair Oil Pressure Test Plug Replacement Removal Procedure 1. Remove the pressure tap plug (2) and O-ring (1) on the bottom of the converter housing near the control main filter. 2. Remove the O-ring from the plug and discard it. Installation Procedure 1. Install a new O-ring (1) on the pressure tap plug (2). 2. Notice: Refer to Fastener Notice in Service Precautions. Install the plug and O-ring into the converter housing. ^ Tighten the plug to 12 Nm (108 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > Electrical Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > Electrical Specifications > Page 7110 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 7111 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E Transmission Speed Sensor: Diagrams Automatic Transmission - 4L80-E/4L85-E Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 7114 Transmission Speed Sensor: Diagrams Automatic Transmission - Allison Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 7115 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E Transmission Speed Sensor: Service and Repair Automatic Transmission - 4L80-E/4L85-E Input Shaft Speed Sensor Replacement Input Shaft Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1). 5. Inspect the input speed sensor (1) for any evidence of damage. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7118 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the input speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector (1). 5. Lower the vehicle. Output Shaft Speed Sensor Replacement Output Shaft Speed Sensor Replacement Removal Procedure Important: This procedure is for 2-wheel drive (2WD) vehicles only. If the vehicle is equipped with 4-wheel drive (4WD), the output speed sensor is located on the transfer case. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7119 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2). 5. Inspect the output speed sensor (2) for any evidence of damage. Installation Procedure 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the output speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7120 4. Connect the output speed sensor (2) electrical connector. 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7121 Transmission Speed Sensor: Service and Repair Automatic Transmission - Allison Speed Sensor Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Be sure the vehicle ignition is turned off. 2. Disconnect the external wiring harness from the speed sensor. 3. Remove the bolt (1) from the speed sensor and carefully remove the speed sensor (2). Installation Procedure 1. Important: Do not rotate the sensor in its retaining bracket. Changing the sensor/bracket orientation may cause improper operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7122 Install a new a O-ring (3) on the speed sensor (2). Lubricate the O-ring with clean transmission fluid. 2. Install the new speed sensor (2) into the speed sensor bore. Align the hole in the retaining bracket with the bolt hole in the speed sensor boss. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor bolt (1). ^ Tighten bolt (1) to 12 Nm (108 inch lbs.). 4. Reconnect the external wiring harness to the speed sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Electrical Specifications Transmission Temperature Sensor/Switch: Electrical Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Electrical Specifications > Page 7127 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Electrical Specifications > Page 7128 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Component Locations Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Component Locations > Page 7131 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-038D > Sep > 06 > A/T - Poor Performance/MIL ON/DTC P0757 Valve Body: Customer Interest A/T - Poor Performance/MIL ON/DTC P0757 Bulletin No.: 01-07-30-038D Date: September 12, 2006 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P0757 Set, Malfunction Indicator Lamp (MIL) Illuminated, Poor Performance of Transmission, Transmission Slipping (Clean Transmission Valve Body and Case Oil Passages of Debris) Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X with 4L60-E/4L65-E/4L70-E Automatic Transmission (RPOs M30/M32/M70) Supercede: This bulletin is being revised to add the 2007 model year and the 4L70-E transmission. Also, information has been added to Condition, Cause and Correction. Please discard Corporate Bulletin Number 01-07-30-038C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: An illuminated MIL where DTC P0757 is found as a history code in the PCM or TCM. No 3rd and 4th gear. The transmission does not shift correctly. The transmission feels like it shifts to Neutral or a loss of drive occurs. The vehicle free wheels above 48 km/h (30 mph). High RPM needed to overcome the free wheeling. Cause This condition may be caused by any of the following: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-038D > Sep > 06 > A/T - Poor Performance/MIL ON/DTC P0757 > Page 7140 Chips or debris plugging the bleed orifice of the 2-3 shift solenoid (367). This will cause the transmission to stay in 2nd gear when 3rd gear is commanded and return to 1st gear when 4th gear is commanded. A 2-3 shift valve (368) or 2-3 shuttle valve (369) that is stuck, restricted and/or hung-up in its bore. This condition may also be an indication of a damaged 2-4 band or 3-4 clutches. This clutch damage may generate debris causing the 2-3 shift valve line-up to stick in the valve body bore and set DTC P0757. Correction Inspect the condition of the transmission fluid for signs of overheat or a burnt odor. If either is noted, the transmission should be disassembled for further investigation and repaired as needed. Inspect the inside of the oil pan for signs of clutch friction material. A small amount of friction material in the bottom of the pan is normal. If a large amount of clutch material is noted in the fluid or bottom pan, the transmission should be disassembled for further investigation and repaired as needed. Inspect and clean the 2-3 shift valve (368), the 2-3 shuttle valve (369) and the valve bore of debris/metal chips. Inspect and clean the 2-3 shift solenoid (367B) opening of debris/metal chips. While inspecting the 2-3 shift solenoid (367B), look for a screen over the solenoid opening. If the solenoid DOES NOT have a screen, replace the solenoid. All current GMSPO stock shift solenoids have a screen over the solenoid opening. If clutch debris is found, it is also very important to inspect the pressure control (PC) solenoid valve fluid screens. Clean or replace the PC solenoid as necessary. It is also important to flush and flow check the transmission oil cooler using J 45096. Refer to SI "Automatic Transmission Oil Cooler Flushing and Flow Test" for the procedure. Refer to the appropriate Service Manual for additional diagnostic information and service procedures. Warranty Information For repairs performed under warranty, use the applicable published labor code and information. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-038D > Sep > 06 > A/T - Poor Performance/MIL ON/DTC P0757 Valve Body: All Technical Service Bulletins A/T - Poor Performance/MIL ON/DTC P0757 Bulletin No.: 01-07-30-038D Date: September 12, 2006 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P0757 Set, Malfunction Indicator Lamp (MIL) Illuminated, Poor Performance of Transmission, Transmission Slipping (Clean Transmission Valve Body and Case Oil Passages of Debris) Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X with 4L60-E/4L65-E/4L70-E Automatic Transmission (RPOs M30/M32/M70) Supercede: This bulletin is being revised to add the 2007 model year and the 4L70-E transmission. Also, information has been added to Condition, Cause and Correction. Please discard Corporate Bulletin Number 01-07-30-038C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: An illuminated MIL where DTC P0757 is found as a history code in the PCM or TCM. No 3rd and 4th gear. The transmission does not shift correctly. The transmission feels like it shifts to Neutral or a loss of drive occurs. The vehicle free wheels above 48 km/h (30 mph). High RPM needed to overcome the free wheeling. Cause This condition may be caused by any of the following: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-038D > Sep > 06 > A/T - Poor Performance/MIL ON/DTC P0757 > Page 7150 Chips or debris plugging the bleed orifice of the 2-3 shift solenoid (367). This will cause the transmission to stay in 2nd gear when 3rd gear is commanded and return to 1st gear when 4th gear is commanded. A 2-3 shift valve (368) or 2-3 shuttle valve (369) that is stuck, restricted and/or hung-up in its bore. This condition may also be an indication of a damaged 2-4 band or 3-4 clutches. This clutch damage may generate debris causing the 2-3 shift valve line-up to stick in the valve body bore and set DTC P0757. Correction Inspect the condition of the transmission fluid for signs of overheat or a burnt odor. If either is noted, the transmission should be disassembled for further investigation and repaired as needed. Inspect the inside of the oil pan for signs of clutch friction material. A small amount of friction material in the bottom of the pan is normal. If a large amount of clutch material is noted in the fluid or bottom pan, the transmission should be disassembled for further investigation and repaired as needed. Inspect and clean the 2-3 shift valve (368), the 2-3 shuttle valve (369) and the valve bore of debris/metal chips. Inspect and clean the 2-3 shift solenoid (367B) opening of debris/metal chips. While inspecting the 2-3 shift solenoid (367B), look for a screen over the solenoid opening. If the solenoid DOES NOT have a screen, replace the solenoid. All current GMSPO stock shift solenoids have a screen over the solenoid opening. If clutch debris is found, it is also very important to inspect the pressure control (PC) solenoid valve fluid screens. Clean or replace the PC solenoid as necessary. It is also important to flush and flow check the transmission oil cooler using J 45096. Refer to SI "Automatic Transmission Oil Cooler Flushing and Flow Test" for the procedure. Refer to the appropriate Service Manual for additional diagnostic information and service procedures. Warranty Information For repairs performed under warranty, use the applicable published labor code and information. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Valve Body: All Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 7155 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 7156 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 7157 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Valve Body: All Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 7167 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 7168 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 7169 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E Valve Body: Service and Repair Automatic Transmission - 4L80-E/4L85-E Valve Body and Pressure Switch Replacement ^ Tools Required J 25025-5 Valve Body Align Pin - J 36850 Transjel® Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. ^ Important: The following components can be serviced without removing the valve body: The 2-3 solenoid (1) ^ The internal wiring harness (2) ^ The 1-2 shift solenoid (3) ^ The transmission fluid temperature sensor (4) ^ The transmission fluid pressure manual valve position switch (5) ^ The pressure control solenoid (6) ^ The torque converter clutch pulse width modulation (TCC PWM) solenoid (7) 2. Remove the fluid level indicator. 3. Remove the transmission filter. 4. Disconnect the internal wire harness from the transmission fluid pressure (TFP) manual valve position switch. Important: Use care not to loose the 5 O-rings that are located between the TFP manual valve position switch and the valve body. 5. Remove the valve body bolts (1) that retain the (TFP) manual valve position switch (2). 6. Remove the TFP manual valve position switch. 7. Disconnect the internal wiring harness electrical connectors from the remaining valve body electrical components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7172 8. Remove the lube oil pipe bolt (6) and retainer (7). 9. Remove the lube oil pipe (5). 10. Remove the manual shaft detent spring bolt and spring (3). Important: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. 11. Remove the remaining valve body bolts. 12. Carefully lower the valve body from the transmission. Use care not to drop the manual shaft valve. 13. Remove the valve body (2) which includes the following: ^ The accumulator housing (1) ^ The valve body to the spacer plate gasket ^ The spacer plate 14. Remove the manual valve (1) from the valve body. 15. Inspect the manual valve for nicks and burrs. 16. Remove the spacer plate to case gasket (2) from the case. The gasket may stick to the spacer plate. 17. Remove the PWM screen (1) from the case passage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7173 18. Remove the manual 2-1 band servo (1). 19. Remove the servo piston cushion spring (2). 20. Remove the manual 2-1 band servo piston pin retainer ring (4). 21. Remove the manual 2-1 band servo piston pin (1). 22. Remove the manual 2-1 band servo piston seal (2). 23. Important: Do not use a magnet in order to remove the checkballs. Using a magnet to remove the checkballs may magnetize the checkballs, causing metal particles to stick. Remove the 8 checkballs (9 for some models). Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7174 1. Install the 8 checkballs (9 for some models) into the transmission case passages. ^ The checkball marked as number 2, is used on RCP, RDP, ZJP and ZLP models only ^ To hold the checkballs in place, use the J 36850. 2. Install the PWM screen into the valve body. 3. Install a new manual 2-1 band servo piston seal (2) onto the manual 2-1 band servo piston (3). 4. Install the manual 2-1 band servo piston pin (1) into the manual 2-1 band servo piston (3). 5. Install the manual 2-1 band servo piston pin retainer ring (4). 6. Install the manual 2-1 band servo piston cushion spring (2). 7. Important: Make certain that the tapered end of the manual 2-1 band servo piston pin contacts the manual 2-1 band. Install the manual 2-1 band servo piston (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7175 8. Install the manual valve (1) into the valve body. 9. To aid in alignment and assembly, install J 25025-5. 10. Install the valve body gasket (6). 11. Install the valve body (5). Attach the manual valve to the detent lever while installing the valve body. 12. Install the transmission fluid pressure manual valve position switch (2). 13. Install the transmission fluid pressure manual valve position switch bolts (1) finger tight. 14. Tighten the bolts in the order shown. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 15. Remove J 25025-5. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7176 16. Install the manual shaft detent roller and spring (3) and bolts. 17. Install the 2 wiring harness clips (1) and bolts (2). 18. Install the wiring harness clip (1) and bolts (2). 19. Install the lube oil pipe (5) with the short end into the valve body. 20. Install the lube oil pipe retainer (7) and the bolt (6). 21. Notice: Refer to Fastener Notice in Service Precautions. Install the valve body bolts and tighten in the order shown. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 22. Install the remaining valve body bolts. ^ Tighten the bolts to 11 Nm (97 inch lbs.). 23. Connect the internal wiring harness to the valve body electrical components. 24. Install the transmission filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7177 Valve Body: Service and Repair Automatic Transmission - Allison Control Valve Body Replacement Control Valve Body Replacement ^ Tools Required - J 44257 Wiring Harness Connector Remover - J 44247 Internal Wiring Harness Installer Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the external wiring harness from the main transmission connector. Use the J 44257, if connector is not easily accessible. 2. Remove the oil pan and suction filter. 3. Important: The transmission main connector is actually one end of the internal harness that protrudes through the main housing. Place a 30 mm (1 3/16 inch) 12-point deep socket or box-end (2) over the connector (1). 4. Push inward on the socket or wrench to release the retainer feet that attach the connector (1) to the main housing. 5. Remove the wrench. Push inward on the electrical connector to separate it from the main housing. This allows the internal wiring harness to remain with the control valve assembly as it is removed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7178 6. Remove the 2 detent spring bolts (3). Remove the detent spring assembly (2). 7. Important: As the control valve assembly is removed, be careful not to lose the manual selector valve pin or allow the manual selector valve to slide out of the control valve assembly. Remove 11 bolts at locations marked (1) and 4 bolts at locations marked (2). Support the control valve assembly (about 10 pounds) and remove the last bolt marked (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7179 8. Lower the control valve assembly (1) to clear the dowel pins (2) in the main housing. 9. Move the control valve assembly (4) sideways to disengage pin (1) in the manual selector valve (2) from the slot in detent lever (3). Remove the control valve assembly (4). Installation Procedure 1. Move the control valve assembly (4) into position under the main housing. Engage the pin (1) in the manual selector valve (2) into the slot in the detent lever (3). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7180 2. Align control valve assembly (1) with the dowel pins (2) in the main housing. Seat the control valve assembly against the main housing and hold it in position. 3. Install one bolt marked (1) to hold the control valve assembly in place. 4. Notice: Refer to Fastener Notice in Service Precautions. Reinstall the remaining 10 bolts marked (1) and 4 bolts marked (2) that fasten the control valve assembly to the main housing. ^ Tighten the bolts to 12 Nm (108 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7181 5. Push the main transmission connector (2) outward through the hole (1) in the main housing until the retaining feet on the connector are nearing the locked position. 6. Use the J 44247 to complete the seating of the retaining feet that lock the connector (1) into the main housing. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7182 7. Install the detent spring assembly (2) onto the control valve assembly. Confirm that the roller of the detent spring assembly rests on the detent lever (1). 8. Notice: Refer to Fastener Notice in Service Precautions. Install 2 detent spring bolts (3). ^ Tighten the bolts to 12 Nm (108 inch lbs.). 9. Install the oil pan and suction filter. 10. Connect the external wiring harness to the main transmission connector. Control Valve Body Disassemble Control Valve Body Disassemble ^ Tools Required J 33163 Valve Tray Set NOTICE: ^ Transmission damage may occur when control valve assembly springs and other parts are mistakenly interchanged. Interchanging parts can be avoided by observing the following precautions: ^ Tag each part as it is removed. ^ Use J 33163 Valve Tray Set to organize parts and to simplify correct valve body reassembly. ^ Protect control valve assembly parts from damage by observing the following precautions: ^ Handle all valves carefully. ^ Protect control valve assembly parts during removal, cleaning, inspection, and reassembly. ^ Keep the parts in a clean container until the parts are installed. ^ When a valve is installed dry, the weight of the valve is sufficient to move the valve through the valve bore. If a valve does not move freely, the transmission may be damaged . Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7183 1. Position the control valve module on the work table so that the main valve body module is facing up. 2. Remove six bolts (1) and one bolt (2) retaining the reverse signal tube and pressure switch assembly to the main valve body. 3. Remove reverse signal tube (2) from main valve body (3). 4. Remove pressure switch assembly (1) from main valve body (3). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7184 5. Remove two bolts (1) retaining the G solenoid valve body. 6. Remove G solenoid body (2)assembly 7. Remove G solenoid retainer (5) from the bottom of the valve body. 8. Remove G solenoid (3) 9. Remove two O-rings (4) from G solenoid (3). 10. Remove F trim solenoid retainer (1). 11. Remove F trim solenoid (7), sleeve (4), valve (3), and spring (2). 12. Remove O-rings (5)and (6) from F trim solenoid (7). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7185 13. Remove D ON/OFF shift solenoid retainer (1). 14. Remove D ON/OFF shift solenoid (4). 15. Remove O-rings (2) and (3) from D ON/OFF shift solenoid (4). 16. Remove E ON/OFF shift solenoid retainer (1). 17. Remove E ON/OFF shift solenoid (4). 18. Remove O-rings (2) and (3) from E ON/OFF shift solenoid (4). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7186 19. Remove three bolts (1) that retain A/B solenoid bracket (2) to main valve body (3). 20. Remove A/B solenoid bracket (1), two accumulator springs (2), and two accumulator plugs (3). 21. Remove A trim solenoid (15), valve (13), spring (12), if present, valve (11), and spring (10). 22. Remove B trim solenoid (9), valve (7), valve (6), and spring (5). 23. Remove O-ring (14) from A trim solenoid (15). 24. Remove O-ring (8) from B trim solenoid (9). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7187 25. Position the control valve module on the work table so that shift valve body (1) is facing up. 26. Remove C ON/OFF shift solenoid retainer (2). 27. Remove C ON/OFF shift solenoid (5). 28. Remove O-rings (3) and (4) from C ON/OFF shift solenoid (5). 29. Remove eleven bolts (1) retaining the shift valve body and the main valve body together. 30. Position the control valve module on the work table so that the main valve body is facing up. Reinstall four bolts (1) so that the bolts are partially threaded into the shift valve body and protrude from the main valve body. 31. Position the control valve module on edge so that the top and bottom are vertical. 32. Gently tap the bolts until the module separates. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7188 33. Position the control valve assembly on the work table so that shift valve body (1) is facing up. 34. Separate shift valve body assembly (1), separator plate (2), and main valve body assembly (4). Disassembly of Shift Valve Body Disassembly of Shift Valve Body ^ Tools Required J 33163 Valve Tray Set - J 43773Valve Spring Compressor 1. Using J 43773 (2) , compress the C shift valve spring until retaining clip (1) is loose. Remove retaining clip (1). 2. Remove spring (2) and C shift valve (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7189 3. Using J 43773 (2), compress the E shift valve spring until retaining clip (1) is loose. Remove retaining clip (1). 4. Remove plug (3), spring (2), and E shift valve (1). 5. Using J 43773 (2), compress the D shift valve spring until retaining clip (1) is loose. Remove retaining clip (1). 6. Remove plug (3), spring (2), and D shift valve (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7190 7. Using J 43773 (2), compress the control main valve spring until retaining clip (1) is loose. Remove retaining clip (1). 8. Remove spring (2) and control main valve (1). 9. Remove solenoid screen (1). Control Valve Body Cleaning and Inspection Control Valve Body Cleaning and Inspection Clean and Inspect ^ Tools Required J 33163 Valve Tray Set Notice: ^ Transmission damage may occur when control valve assembly springs and other parts are mistakenly interchanged. Interchanging parts can be avoided by observing the following precautions: ^ Tag each part as it is removed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7191 ^ Use J 33163 Valve Tray Set to organize parts and to simplify correct valve body reassembly. ^ Protect control valve assembly parts from damage by observing the following precautions: ^ Handle all valves carefully. ^ Protect control valve assembly parts during removal, cleaning, inspection, and reassembly. ^ Keep the parts in a clean container until the parts are installed. 1. Clean all removed parts with volatile mineral spirits or other similar cleaning agent. 2. Clean fluid passages by working a piece of soft wire through the passage and flushing with mineral spirits. Dry the passages with compressed air. 3. Inspect valves for wear, nicks, or scratches. Remove minor imperfections with a soft stone or crocus cloth. Replace any damaged valves. 4. Inspect springs for signs of overheating, permanent set, or wear. Replace suspect springs. 5. Inspect mating surfaces for nicks, burrs, scratches, or foreign matter. Remove any defects with crocus cloth or a soft stone. Replace damaged parts. 6. Inspect bores for wear, scratches, and grooves. Remove scratches and burrs with crocus cloth. Replace deeply grooved or scratched parts. 7. Inspect threaded parts for burred or damaged threads. Remove burrs with a soft stone or fine file. 8. Inspect threaded openings for damaged threads. Correct damaged threads with a correctly sized tap. A/B Solenoid Bracket Inspection 1. Measure the angle between the surfaces of the A/B solenoid bracket (1) (Angle A). 2. Adjust the bracket surfaces until the angle between the surfaces is 82.84 degrees. Control Valve Body Assemble Control Valve Body Assemble ^ Tools Required J 33163 Valve Tray Set - J 43773 Valve Spring Compressor Shift Valve Body Assemble Important: ^ Transmission damage may occur when control valve assembly springs and other parts are mistakenly interchanged. Interchanging parts can be avoided by the following: ^ Tag each part as it is removed. ^ Use Valve Tray Set to organize parts and to simplify correct valve body reassembly. ^ Protect control valve assembly parts from damage observing the following precautions ^ Handle all valves carefully. ^ Protect control valve assembly parts during removal, cleaning, inspection, and reassembly. ^ Keep parts in a clean container until the parts are installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7192 1. Install solenoid screen (1). Ensure solenoid screen (1) is installed to a depth of 0.50-1.00 mm (0.20-0.039 inch) (Dimension A) below the shift valve body surface, as shown. 2. Install control main valve (1) and spring (2). 3. Using Valve Spring Compressor J 43773 (2), compress the valve spring. 4. Install retaining clip (1). Make Sure retaining clip (1) is below the valve body surface. 5. Install D shift valve (1), spring (2), and plug (3). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7193 6. Using Valve Spring Compressor J 43773 (2), compress the valve spring. 7. Install retaining clip (1). Make Sure the retaining clip is below the valve body surface. 8. Install E shift valve (1), spring (2), and plug (3). 9. Using Valve Spring Compressor J 43773 (2), compress the valve spring. 10. Install retaining clip (1). Make sure the retaining clip is below the valve body surface. 11. Install C shift valve (1), spring (2), and plug. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7194 12. Using Valve Spring Compressor J 43773 (2), compress the valve spring. 13. Install retaining clip (1). Make Sure the retaining clip is below the valve body surface. Control Valve Body Assembly 1. Position main valve body assembly (4) on the work table so that the worm-track side is up. 2. Align separator plate (2) with main valve body dowel pins (3). 3. Install separator plate (2). 4. Align shift valve body assembly (1) with main valve body dowel pins (3). 5. Install the shift valve body assembly onto the separator plate. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7195 6. Position the control valve assembly on the work table so that the main valve body is facing up. 7. Install fourteen bolts (1) retaining the valve bodies together. ^ Tighten the bolts to 12 Nm (9 ft. lbs.). 8. Position the control valve assembly on the work table so that the shift valve body is up. 9. Important: ^ O-ring (4) is slightly larger than O-ring (3). ^ P/N 29536833 is printed on C ON/OFF shift solenoid (5). Install solenoid O-ring (4) onto C ON/OFF shift solenoid (5). 10. Install solenoid O-ring (3) onto C ON/OFF shift solenoid (5). 11. Align C ON/OFF shift solenoid (5) so that the electrical connector points away from the nearest dowel pin and is parallel to the separator plate as shown. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7196 12. Position the control valve assembly on the work table so that main valve body (16) is facing up. 13. Important: P/N 29533074 is printed on the A trim solenoid. Install solenoid O-ring (14) onto A trim solenoid (15). 14. Important: P/N 29533075 is printed on the B trim solenoid. Install solenoid O-ring (8) onto B trim solenoid (9). 15. Install spring (10) , A trim valve (11), spring (12), and trim gain valve (13). 16. Install spring (5), B trim valve (6) and trim gain valve (7). 17. Install A trim solenoid (15) so that the electrical connection faces up. Do not seat the solenoid. 18. Install B trim solenoid (9) so the electrical connection faces up. Do not seat the solenoid. 19. Align two accumulator plugs (3) so that their spring bores face up. 20. Install two accumulator plugs (3) and two accumulator springs (2). 21. Push the A and B trim solenoids into their bores until the solenoids seat. 22. Align A/B solenoid bracket (1) with main valve body dowel pin (4). 23. Install A/B solenoid bracket (10) so that the A and B trim solenoids, the accumulator plugs, and the accumulator springs are retained against the valve body. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7197 24. Install three bolts (1) retaining A/B solenoid bracket (2). ^ Tighten bolts (1) to 12 Nm (9 ft. lbs.). 25. Important: ^ The solenoid O-rings are brown. ^ O-ring (3) is slightly larger than O-ring (2). ^ P/N 29536833 is printed on the E ON/OFF shift solenoid. Install solenoid O-ring (3) onto E ON/OFF shift solenoid (4). 26. Install solenoid O-ring (2) onto E ON/OFF shift solenoid (4). 27. Install E ON/OFF shift solenoid (4) so that the electrical connection faces up. seat the solenoid. 28. Install solenoid retainer (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7198 29. Important: ^ The solenoid O-rings are brown. ^ O-ring (3) is slightly larger than O-ring (2). ^ P/N 29536833 is printed on the D ON/OFF shift solenoid. Install solenoid O-ring (3) onto D ON/OFF shift solenoid (4). 30. Install solenoid O-ring (2) onto D ON/OFF shift solenoid (4). 31. Install E ON/OFF shift solenoid (4) so that the electrical connection faces up. seat the solenoid. 32. Install solenoid retainer (1). 33. Important: ^ The solenoid O-rings are brown. ^ O-ring (6) is slightly larger than O-ring (5). Install solenoid O-ring (6) onto F ON/OFF shift solenoid (7). 34. Install solenoid O-ring (5) onto F ON/OFF shift solenoid (7). 35. Install F trim spring (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7199 36. Install F trim valve (3) 37. Install F trim sleeve (4) 38. Align F trim solenoid (7) so that the electrical connection faces up. 39. Install F trim solenoid F. Seat the solenoid. 40. Install solenoid retainer (1). 41. Install O-rings (4) onto G solenoid (3). 42. Install G solenoid (3) 43. Install G solenoid retainer (5) into the bottom of the valve body. 44. Install G solenoid body (2) assembly. 45. Important: Four bolts pass through the G solenoid valve body to retain the control valve body assembly to the main housing. Install these bolts when installing the control valve body assembly. Install the two bolts (1) retaining the G solenoid valve body and the shift valve body to the main valve body. ^ Tighten bolts to 12 Nm (9 ft. lbs.). 46. Align the bolts holes and alignment tabs of pressure switch assembly (1) with the pressure switch assembly holes in main valve body (1). 47. Install pressure switch assembly (1) onto main valve body (3). 48. Install reverse signal tube (2) onto the main valve body. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7200 49. Important: Seven bolts retain the reverse signal tube and the pressure switch assembly. ^ Bolt (2) is slightly longer than the other bolts (1). ^ The pressure switch assembly is retained by five bolts (1) and by bolt (2). ^ The reverse signal tube is retained by one bolt (1) and by bolt (2). Install six bolts (1) and one bolt (2) retaining the reverse signal tube and the pressure switch assembly to the main valve body. ^ Tighten bolts (1) and bolt (2) to 12 Nm (9 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 01-07-30-002E > Sep > 05 > Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Wiring Harness: Customer Interest Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Bulletin No.: 01-07-30-002E Date: September 23, 2005 TECHNICAL Subject: Malfunction Indicator Lamp (MIL) On, Transmission Stuck in Second or Third Gear, Instrument Cluster Inoperative (Verify and Repair Source of Voltage Loss In Transmission Solenoid Power Supply Circuit) Models: 2006 and Prior GM Passenger Cars and Light Duty Trucks 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E, 4L65-E, 4L80-E or 4L85-E Automatic Transmission (RPOs M30, M32, M33, MT1, MN8) Supercede: This bulletin is being revised to update model years, add additional models and add additional diagnostic information. Please discard Corporate Bulletin Number 01-07-30-002D (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions: ^ The Malfunction Indicator Lamp (MIL) is ON. ^ The transmission is defaulted to second gear (4L80/85-E). ^ The transmission is defaulted to third gear (4L60/65-E). ^ The instrument cluster is inoperative. Upon investigation, one or all of the diagnostic trouble codes (DTCs) P0740, P0753, P0758, P0785, P0787, P0973, P0976, P1860, P2761, P2764 and P2769 may be set depending on the vehicle. Cause The most likely cause of this condition may be a loss of voltage to the transmission solenoid power supply circuit. This condition may also be the result of an incorrect installation of an aftermarket electronic device such as a remote starter or alarm system. Correction Important: If the vehicle is equipped with an aftermarket electronic device and the DTCs are being set when the device is being used, verify that the appropriate fuse is being supplied battery voltage during operation. If voltage is not present at this fuse, these DTCs will be set due to lack of voltage at the solenoids. This condition is most likely to occur with an incorrectly installed remote starting system. If this is the case, refer the customer to the installer of the system for corrections. ANY REPAIRS DUE TO AFTERMARKET INSTALLATION OF ACCESSORIES IS A NON-WARRANTABLE ITEM. 1. With the ignition switch in the RUN position, test for battery voltage at the circuit fuse in the transmission solenoid power supply circuit. Refer to the appropriate SI Document for the transmission solenoid power supply circuit information. 2. If battery voltage is present at the fuse, inspect the ignition voltage circuit between the fuse and the transmission for possible opens. 3. If battery voltage is not present at the fuse, test for continuity between the fuse and the ignition switch. If NO continuity is between the fuse and the ignition switch, repair the open in that circuit. 4. If you have continuity between the fuse and the ignition switch, the most likely cause is the ignition switch. Replace the ignition switch using the appropriate Ignition Switch Replacement procedure in SI. Refer to group number 2.188 of the parts catalog for part description and usage of the ignition switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 01-07-30-002E > Sep > 05 > Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's > Page 7209 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 01-07-30-002E > Sep > 05 > Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Wiring Harness: All Technical Service Bulletins Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's Bulletin No.: 01-07-30-002E Date: September 23, 2005 TECHNICAL Subject: Malfunction Indicator Lamp (MIL) On, Transmission Stuck in Second or Third Gear, Instrument Cluster Inoperative (Verify and Repair Source of Voltage Loss In Transmission Solenoid Power Supply Circuit) Models: 2006 and Prior GM Passenger Cars and Light Duty Trucks 2005-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E, 4L65-E, 4L80-E or 4L85-E Automatic Transmission (RPOs M30, M32, M33, MT1, MN8) Supercede: This bulletin is being revised to update model years, add additional models and add additional diagnostic information. Please discard Corporate Bulletin Number 01-07-30-002D (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions: ^ The Malfunction Indicator Lamp (MIL) is ON. ^ The transmission is defaulted to second gear (4L80/85-E). ^ The transmission is defaulted to third gear (4L60/65-E). ^ The instrument cluster is inoperative. Upon investigation, one or all of the diagnostic trouble codes (DTCs) P0740, P0753, P0758, P0785, P0787, P0973, P0976, P1860, P2761, P2764 and P2769 may be set depending on the vehicle. Cause The most likely cause of this condition may be a loss of voltage to the transmission solenoid power supply circuit. This condition may also be the result of an incorrect installation of an aftermarket electronic device such as a remote starter or alarm system. Correction Important: If the vehicle is equipped with an aftermarket electronic device and the DTCs are being set when the device is being used, verify that the appropriate fuse is being supplied battery voltage during operation. If voltage is not present at this fuse, these DTCs will be set due to lack of voltage at the solenoids. This condition is most likely to occur with an incorrectly installed remote starting system. If this is the case, refer the customer to the installer of the system for corrections. ANY REPAIRS DUE TO AFTERMARKET INSTALLATION OF ACCESSORIES IS A NON-WARRANTABLE ITEM. 1. With the ignition switch in the RUN position, test for battery voltage at the circuit fuse in the transmission solenoid power supply circuit. Refer to the appropriate SI Document for the transmission solenoid power supply circuit information. 2. If battery voltage is present at the fuse, inspect the ignition voltage circuit between the fuse and the transmission for possible opens. 3. If battery voltage is not present at the fuse, test for continuity between the fuse and the ignition switch. If NO continuity is between the fuse and the ignition switch, repair the open in that circuit. 4. If you have continuity between the fuse and the ignition switch, the most likely cause is the ignition switch. Replace the ignition switch using the appropriate Ignition Switch Replacement procedure in SI. Refer to group number 2.188 of the parts catalog for part description and usage of the ignition switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 01-07-30-002E > Sep > 05 > Electrical - A/T Stuck in 2nd/3rd Gear/MIL ON/DTC's > Page 7215 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Page 7216 Wiring Harness: Service and Repair Wiring Harness Replacement ^ Tools Required J 44257 Wiring Harness Connector Remover - J 44247 Internal Wiring Harness Installer Removal Procedure 1. Remove the oil pan and suction filter. 2. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the external wiring harness from the main transmission connector. Use J 44257, if connector is not easily accessible. 3. Important: The main transmission connector is actually one end of the internal wiring harness that protrudes through the main housing. Place a 30 mm or 1 3/16 inch 12-point deep socket or box-end wrench (2) over the main transmission connector (1). 4. Push inward on the socket or wrench to release the retaining "feet" that attach the connector (1) to the main housing. 5. Remove the wrench. Push inward on the electrical connector to separate it from the main housing. 6. Disconnect the internal wiring harness connectors (1) from solenoids A through G and from the pressure switch assembly. 7. Important: The solenoid retainers for E and D solenoid also retain tabs on the wiring harness U-channel. The solenoids will remain in position even after the solenoid retainers are removed. Remove the solenoid retainers (2) for solenoids E and D. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Page 7217 8. Remove the internal wiring harness from the transmission. Installation Procedure 1. Align the tabs (8) on the new wiring harness U-channel with the solenoid retainer slots for solenoids E (3) and D (2) on the control valve assembly. Install the solenoid retainers (14) for the E (3) and D (4) solenoids. 2. Important: The internal wiring harness connectors (7), (9)-(13), and (15) should be in the correct position for installation because of their pre-assembled position in the U-channel. Attach the internal wiring harness connectors to solenoids A through F and to the pressure switch assembly. ^ Connector (13) goes to solenoid (6). ^ Connector (12) goes to solenoid (4). ^ Connector (7) goes to solenoid (5). ^ Connector (10) goes to solenoid (2). ^ Connector (11) goes to solenoid (3). ^ Connector (9) goes to solenoid (1). ^ Connector (15) goes to solenoid (16) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Page 7218 3. Push the main transmission connector (2) outward through hole (1) in the main housing until the retaining "feet" on the connector are near the locked position. 4. Use J 44247 to seat the retaining "feet" on transmission connector (1). 5. Install the oil pan and suction filter. 6. Connect the external wiring harness to the main transmission connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications HYDRAULIC CLUTCH FLUID 5-SPEED TRANS. Hydraulic Clutch Fluid (GM Part No. U.S. 12345347, in Canada 10953517) or equivalent DOT-3 brake fluid. 6-SPEED TRANS. Hydraulic Clutch Fluid. Use only GM Part No. U.S. 88958860, in Canada 88901244, DOT-4 brake fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair Clutch Master Cylinder: Service and Repair Clutch Master Cylinder Replacement Removal Procedure 1. Disconnect the clutch pedal position switch electrical connector (1). 2. Push the clutch pedal in and squeeze the pushrod bushing tabs in, in order to release the pushrod bushing from the clutch pedal. 3. If equipped with a NV 3500 or NV 4500 transmission, disconnect the clutch actuator cylinder to clutch master cylinder quick connect fitting. 4. Remove the clutch master cylinder clip from the brake pressure module valve pipe. 5. If equipped with a ZF S6-650 transmission, disconnect the clutch actuator cylinder to clutch master cylinder quick connect fitting. 6. Rotate the clutch master cylinder 45 degrees clockwise to the unlocked position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Page 7227 7. If equipped with a NV 3500 or NV 4500 transmission, remove the clutch master cylinder. 8. If equipped with a ZF S6-650 transmission, remove the clutch master cylinder. Installation Procedure 1. If equipped with a ZF S6-650 transmission, install the clutch master cylinder. 2. If equipped with a NV 3500 or NV 4500 transmission, install the clutch master cylinder. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Page 7228 3. Push in and rotate the clutch master cylinder 45 degrees counterclockwise to the locked position. 4. If equipped with a ZF S6-650 transmission, disconnect the clutch actuator cylinder to clutch master cylinder quick connect fitting. 5. If equipped with a NV 3500 or NV 4500 transmission, disconnect the clutch actuator cylinder to clutch master cylinder quick connect fitting. 6. Install the clutch master cylinder clip to the brake pressure module valve pipe. 7. Apply light pressure to the clutch pedal to couple the pushrod socket to the clutch pedal. 8. Connect the clutch pedal position switch electrical connector (1). 9. Pump the clutch pedal 3 time prior to starting the vehicle to ensure connection is complete. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > NV3500/NV4500 Transmissions Clutch Slave Cylinder: Service and Repair NV3500/NV4500 Transmissions Clutch Actuator Cylinder Replacement (NV3500/NV4500 Transmissions) Removal Procedure 1. Remove the manual transmission. 2. Remove the clutch actuator cylinder bolts. 3. Remove the clutch actuator cylinder. If required, the clutch release bearing can be removed from the clutch actuator cylinder for replacement. Installation Procedure 1. Install the clutch actuator cylinder. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the clutch actuator cylinder bolts. ^ Tighten the bolts to 8 Nm (71 inch lbs.). 3. Install the manual transmission. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > NV3500/NV4500 Transmissions > Page 7233 Clutch Slave Cylinder: Service and Repair ZF S6-650 Transmission Clutch Actuator Cylinder Replacement (ZF S6-650 Transmission) Removal Procedure 1. Remove the manual transmission. 2. Remove the clutch actuator cylinder bolts. 3. Remove the clutch actuator cylinder. If required, the clutch release bearing can be removed from the clutch actuator cylinder for replacement. Installation Procedure 1. Install the clutch actuator cylinder. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the clutch actuator cylinder bolts. ^ Tighten the bolts to 8 Nm (71 inch lbs.). 3. Install the manual transmission. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair Clutch Pedal Assembly: Service and Repair Clutch Pedal Replacement Removal Procedure 1. Remove the driver's side knee bolster and deflector. 2. Disconnect and reposition the junction block. 3. Disconnect the clutch pedal position switch electrical connector (1). 4. Push the clutch pedal in and squeeze the pushrod bushing tabs in, in order to release the pushrod bushing from the clutch pedal. 5. If equipped with a NV 3500 or NV 4500 transmission, disconnect the clutch master cylinder to clutch actuator cylinder quick connect fitting. 6. Remove the clutch master cylinder clip from the brake pressure module valve pipe. 7. If equipped with a ZF S6-650 transmission, disconnect the clutch master cylinder to clutch actuator cylinder quick connect fitting. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair > Page 7237 8. Rotate the clutch master cylinder 45 degrees clockwise to the unlocked position. Important: Complete removal of the clutch master cylinder is not required. 9. Pull the clutch master cylinder out until the pushrod socket is not touching the clutch pedal. 10. Remove the clutch pedal to clutch pedal bracket bolt. 11. Remove the clutch pedal to brake module bolts. 12. Remove the clutch pedal sub-assembly. Installation Procedure 1. Install the clutch pedal sub-assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair > Page 7238 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the clutch pedal to brake module bolts. ^ Tighten the bolts to 50 Nm (37 ft. lbs.). 3. Install the clutch pedal to clutch pedal bracket bolt. ^ Tighten the bolt to 36 Nm (27 ft. lbs.). 4. Push the clutch master cylinder in until the pushrod socket is touching the clutch pedal. 5. Push in and rotate the clutch master cylinder 45 degrees counterclockwise to the locked position. 6. If equipped with a ZF S6-650 transmission, connect the clutch master cylinder to clutch actuator cylinder quick connect fitting. 7. If equipped with a NV 3500 or NV 4500 transmission, connect the clutch master cylinder to clutch actuator cylinder quick connect fitting. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair > Page 7239 8. Install the clutch master cylinder clip to the brake pressure module valve pipe. 9. Apply light pressure to the clutch pedal to couple the pushrod socket to the clutch pedal. 10. Connect the clutch pedal position switch electrical connector (1). 11. Pump the clutch pedal 3 time prior to starting the vehicle to ensure connection is complete. 12. Position and connect the junction block. 13. Install the driver's side knee bolster and deflector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Diagrams Clutch Start Switch (M/T) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Service and Repair Clutch Release Bearing: Service and Repair Release Bearing Replacement Removal Procedure 1. Remove the manual transmission. 2. Remove the clutch release bearing. ^ Rotate the bearing in either direction ^ The compression spring load will push the release bearing off the end of the clutch actuator bearing. Installation Procedure Important: DO NOT use cleaners or chemicals to clean the quill and DO NOT grease the quill. 1. Using a clean dry cloth, clean the exposed area of the actuator cylinder quill. 2. Install the NEW clutch release bearing to the clutch actuator cylinder. ^ Firmly push the clutch release bearing into place. ^ The release bearing will snap over the retainer tab and will be self-retained to the actuator cylinder. 3. Install the manual transmission. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair Pilot Bearing: Service and Repair Pilot Bearing Replacement ^ Tools Required J 43276 Clutch Pilot Bearing Remover - J 38836 Bushing Installer/Clutch Arbor Removal Procedure Notice: When using the J 43276 Clutch Pilot Bearing Remover, always secure the J 43276-1 Clutch Pilot Bearing Remover tool body using a wrench. Do not allow the J 43276-1 tool body to rotate. Failing to do so causes damage to the J 43276-1 tool body. Important: The flywheel spacer (if applicable) must be removed prior to clutch pilot bearing removal. 1. Remove the clutch assembly. 2. Using J 43276 perform the following in order to remove the clutch pilot bearing: 1. Install the J 43276-1 into the clutch pilot bearing. 2. Using a wrench, secure the J 43276-1. 3. Insert the J 43276-2 into the J 43276-1. 4. Rotate the J 43276-2 clockwise into the J 43276-1 until the clutch pilot bearing is completely removed from the crankshaft. 5. Rotate the J 43276-2 counterclockwise to remove the J 43276-2 from the J 43276-1. 6. Remove the J 43276-1 from the tool body. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair > Page 7249 3. Discard the old clutch pilot bearing. Installation Procedure Important: The flywheel spacer (if applicable) must be removed prior to pilot bearing installation. 1. Install a 5/8 inch washer (1) onto the J 38836 or equivalent. 2. Install a NEW clutch pilot bearing (2) onto the tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair > Page 7250 3. Install the NEW clutch pilot bearing into the crankshaft using J 38836. 4. Inspect the clutch pilot bearing for proper installation. 5. Install the clutch assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Technical Service Bulletins > M/T - Revised Pressure Plate Adjustment Procedure Pressure Plate: Technical Service Bulletins M/T - Revised Pressure Plate Adjustment Procedure Bulletin No.: 04-07-31-001 Date: January 21, 2004 SERVICE MANUAL UPDATE Subject: Revised Clutch Pressure Plate Adjustment (Off-Vehicle (6.0L, 6.6L, 8.1L Only)) Models: 2001-2004 Chevrolet Silverado 2001-2004 GMC Sierra with 6.0L, 6.6L or 8.1L Engine This bulletin is being issued to add the Clutch Pressure Plate Adjustment (Off-Vehicle (6.0L, 6.6L, 8.1L only)) procedure to the Clutch sub-section of the Service Manual. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Clutch Pressure Plate Adjustment (Off-Vehicle (6.0L, 6.6L, 8.1L Only)) Important: ^ Use the following procedure when replacing ONLY the clutch disc. The self adjusting clutch pressure plate/cover assembly must be "reset" back to the "unworn" position in order to work properly. Failure to "reset" the cover assembly results in the inability to achieve full clutch release and clutch slippage under full torque. ^ The 6.6L engine uses a "potted" style flywheel and the cover stamping is much shorter to accommodate the flywheel. As a result, to "reset" this clutch, the cover MUST be evenly supported at all six bolt holes in order to keep from bending the cover and to unload the adjuster ring allowing the clutch to be "reset." 1. Place the clutch pressure plate and disc, flange side down, on a press. 2. Compress the pressure plate diaphragm spring fingers until tension is released from the stepped adjusting ring. 3. Using 2 screwdrivers or other suitable tools, place them against 2 of the 3 stepped adjusting ring tension spring stops (1), just ahead of the adjusting ring tension springs. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Technical Service Bulletins > M/T - Revised Pressure Plate Adjustment Procedure > Page 7255 4. Using the screwdrivers, rotate the stepped adjusting ring counterclockwise (compressing the tension springs) until the adjusting ring steps are fully adjusted out, then continue to hold in position. 5. Release the press pressure from the pressure plate diaphragm spring fingers. 6. Release the adjusting ring tension spring stops. 7. Remove the pressure plate and disc from the press. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Technical Service Bulletins > Page 7256 Pressure Plate: Specifications Pressure Plate Bolt .............................................................................................................................. ...................................................... 70 Nm (52 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Technical Service Bulletins > Page 7257 Pressure Plate: Adjustments Clutch Pressure Plate Adjustment (Off-Vehicle (6.0L, 6.6L, 8.1L Only)) Important: ^ Use the following procedure when replacing ONLY the clutch disc. The self adjusting clutch pressure plate/cover assembly must be "reset" back to the "unworn" position in order to work properly. Failure to "reset" the cover assembly results in the inability to achieve full clutch release and clutch slippage under full torque. ^ The 6.6L engine uses a "potted" style flywheel, and the cover stamping is much shorter to accommodate the flywheel, as a result to "reset" this clutch the cover MUST be evenly supported at all six bolt holes in order to keep from bending the cover and to unload the adjuster ring allowing the clutch to be "reset." 1. Place the clutch pressure plate and disc, flange side down, on a press. 2. Compress the pressure plate diaphragm spring fingers until tension is released from the stepped adjusting ring. 3. Using 2 screwdrivers or other suitable tools, place them against 2 of the 3 stepped adjusting ring tension spring stops (1), just ahead of the adjusting ring tension springs. 4. Using the screwdrivers, rotate the stepped adjusting ring counterclockwise (compressing the tension springs) until the adjusting ring steps are fully adjusted out, then continue to hold in position. 5. Release the press pressure from the pressure plate diaphragm spring fingers. 6. Release the adjusting ring tension spring stops. 7. Remove the pressure plate and disc from the press. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Technical Service Bulletins > A/T - Shift Lock Control Feature Function Shift Interlock: Technical Service Bulletins A/T - Shift Lock Control Feature Function Bulletin No.: 03-07-30-043A Date: May 25, 2006 INFORMATION Subject: Information Regarding Automatic Transmission Shift Lock Control Function Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 03-07-30-043 (Section 07 - Transmission/Transaxle). This bulletin is being issued to better explain how the Automatic Transmission Shift Lock Control (formerly known as Brake Transmission Shift Interlock (BTSI)) feature is intended to operate. Revised wording regarding the shift lock control system began appearing in the Owner Manuals beginning with the 2004 model year. The shift lock control feature was intended to prevent drivers from shifting out of Park with the vehicle running without the brakes applied. However, if the ignition switch is in the Accessory (ACC) position, it may be possible on some vehicles to move the shift lever out of Park WITHOUT first activating the brake. The shift lock control system is ONLY active when the ignition switch is in the RUN or ON position. This means that when the ignition switch is in the RUN or ON position, the shift lever cannot be moved out of the Park position without activating the brake. Some owners may feel that the shift lock control system prevents an unattended child from moving the vehicle. Please stress to owners, as stated in the Owner Manual, that children should NEVER be left unattended in a vehicle, even if the ignition key has been removed from the vehicle. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Technical Service Bulletins > Customer Interest for Carrier Bearings: > 09-04-19-001 > Apr > 09 > Drivetrain - Whine or Click Type Noises from Front Axle Carrier Bearings: Customer Interest Drivetrain - Whine or Click Type Noises from Front Axle TECHNICAL Bulletin No.: 09-04-19-001 Date: April 28, 2009 Subject: Whine or Click Type Noises from Front Axle/New Design Front Axle Side Bearing Adjusters (Inspect/Replace with New Lock Rings) Models: 2002-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2002-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2009 GMC Sierra, Yukon, Yukon XL All Equipped with 8.25" Front Axle Condition Some customers may comment about whine or click type noises from the front axle. Upon further investigation, disassembly of the front differential may reveal chipped pinion or ring gear teeth. Cause This condition may be caused by an oversize front bearing side adjuster lock ring allowing the adjuster to move. New Design Lock Adjusters Vs Old Design T-Lock Adjusters Note Front axle housings for old-style (Classic - GMT800) and new-style (GMT900) vehicles are not interchangeable. The new design eliminates the side bearing adjusters movement. The lock adjusters are retained by a pressed in lock ring that maintains the adjuster setting for backlash and side bearing preload. All front axle housings for all model years will use the new design adjusters, and use the new lock ring. The t-lock adjusters are still available, but if a housing replacement is needed, it is necessary to order the lock ring style housing, two of the new adjusters and two of the lock rings. Part numbers are available through the GM Parts catalog. A newly designed 8.25" front axle is in production. The new design eliminates the t-lock side bearing adjusters. The new adjusters are retained by a pressed in lock ring that maintains the adjuster setting for backlash and side bearing preload. This design was phased into production during September, 2006. As a result, in the 2007 model year, both old-style (Classic - GMT800) and new-style (GMT900) vehicles built before the change have the t-lock design adjusters, and both types of vehicles built after the change have the lock ring design adjusters. Correction If no damage is visible and the concern was a whine or click noise, follow the inspect procedure in this bulletin and replace the lock ring. Complete assembly replacement is not necessary if an oversized slipping lock ring was found. Important The bearing adjuster lock rings are not reusable. Inspect New Replacement Part Prior to Installation Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Technical Service Bulletins > Customer Interest for Carrier Bearings: > 09-04-19-001 > Apr > 09 > Drivetrain - Whine or Click Type Noises from Front Axle > Page 7273 Replace the side bearing adjuster lock ring and refer to SI for adjustment. When replacing the side bearing adjuster lock ring, inspect the old locking ring and make sure there are vertical lines in the outer and inner diameter of the ring (1). Next inspect and make sure there is tension when the locking rings are installed. If the locking ring rotates freely around the adjuster, do not use the locking ring. Replace with a new locking ring and make the same inspection. Oversize Lock Rings-Do Not Use The new lock rings will not have any vertical lines (inner or outer). They are imprinted during install. If vertical lines are shown (1), DO NOT USE. Parts Information Refer to GM Parts Catalog. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Carrier Bearings: > 09-04-19-001 > Apr > 09 > Drivetrain - Whine or Click Type Noises from Front Axle Carrier Bearings: All Technical Service Bulletins Drivetrain - Whine or Click Type Noises from Front Axle TECHNICAL Bulletin No.: 09-04-19-001 Date: April 28, 2009 Subject: Whine or Click Type Noises from Front Axle/New Design Front Axle Side Bearing Adjusters (Inspect/Replace with New Lock Rings) Models: 2002-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2002-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2009 GMC Sierra, Yukon, Yukon XL All Equipped with 8.25" Front Axle Condition Some customers may comment about whine or click type noises from the front axle. Upon further investigation, disassembly of the front differential may reveal chipped pinion or ring gear teeth. Cause This condition may be caused by an oversize front bearing side adjuster lock ring allowing the adjuster to move. New Design Lock Adjusters Vs Old Design T-Lock Adjusters Note Front axle housings for old-style (Classic - GMT800) and new-style (GMT900) vehicles are not interchangeable. The new design eliminates the side bearing adjusters movement. The lock adjusters are retained by a pressed in lock ring that maintains the adjuster setting for backlash and side bearing preload. All front axle housings for all model years will use the new design adjusters, and use the new lock ring. The t-lock adjusters are still available, but if a housing replacement is needed, it is necessary to order the lock ring style housing, two of the new adjusters and two of the lock rings. Part numbers are available through the GM Parts catalog. A newly designed 8.25" front axle is in production. The new design eliminates the t-lock side bearing adjusters. The new adjusters are retained by a pressed in lock ring that maintains the adjuster setting for backlash and side bearing preload. This design was phased into production during September, 2006. As a result, in the 2007 model year, both old-style (Classic - GMT800) and new-style (GMT900) vehicles built before the change have the t-lock design adjusters, and both types of vehicles built after the change have the lock ring design adjusters. Correction If no damage is visible and the concern was a whine or click noise, follow the inspect procedure in this bulletin and replace the lock ring. Complete assembly replacement is not necessary if an oversized slipping lock ring was found. Important The bearing adjuster lock rings are not reusable. Inspect New Replacement Part Prior to Installation Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Carrier Bearings: > 09-04-19-001 > Apr > 09 > Drivetrain - Whine or Click Type Noises from Front Axle > Page 7279 Replace the side bearing adjuster lock ring and refer to SI for adjustment. When replacing the side bearing adjuster lock ring, inspect the old locking ring and make sure there are vertical lines in the outer and inner diameter of the ring (1). Next inspect and make sure there is tension when the locking rings are installed. If the locking ring rotates freely around the adjuster, do not use the locking ring. Replace with a new locking ring and make the same inspection. Oversize Lock Rings-Do Not Use The new lock rings will not have any vertical lines (inner or outer). They are imprinted during install. If vertical lines are shown (1), DO NOT USE. Parts Information Refer to GM Parts Catalog. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Service and Repair > All Except 9.75 Inch Axle Carrier Bearings: Service and Repair All Except 9.75 Inch Axle Differential Side Bearings Replacement (All Except 9.75 Inch Axle) ^ Tools Required J 22912-01Split Plate Bearing Puller - J 8092 Universal Driver Handle - 3⁄4 in - 10 - J 21784 Side Bearing Installer - J 22888-D Side Bearing Remover Kit - J 29710 Differential Side Bearing Installer - J 36597 Side Bearing Puller Pilot - 9.25 Axle - J 44420 Differential Bearing and Hub Seal Installer Removal Procedure 1. Remove the differential assembly. 2. Remove the differential side bearings by doing the following: 1. For the 8.6 inch, 9.5 inch, 11.5 inch axles, install the differential assembly into a vise. 2. For the 10.5 inch axle, place a block of wood on each side of the differential assembly.Install the differential assembly into a vise. 3. Install the J 22888-20A (2) and the J 8107-4, 8.6 inch axle, or the J 36597, 9.5 inch or 10.5 inch axle, or the J 8107-5, 11.5 inch (1) axle, over the differential case side bearing bore. 4. Remove the differential side bearings using the J 22888-20A. Installation Procedure 1. For the 8.6 inch, the 9.5 inch, and the 10.5 inch axles, install the differential side bearings by doing the following: 1. In order to protect the differential case, install the J 8107-4, 8.6 inch axle, or the J 36597, 9.5 inch or 10.5 inch axles, in the case on the side opposite the bearing installation. 2. Install the J 21784, 8.6 inch axle, or the J 29710, 9.5 inch or 10.5 inch axles (2), and the J 8092 (1) onto the differential case bearing as shown. 3. Drive the bearing onto the case using the J 21784 or the J 29710 and the J 8092. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Service and Repair > All Except 9.75 Inch Axle > Page 7282 2. For the 11.5 inch axle, install the differential side bearings by doing the following: 1. In order to protect the differential case, install the J 8107-5 in the case on the side opposite the bearing installation. 2. Install the J 44420 (2) and the J 8092 (1) onto the differential case bearing as shown. 3. Drive the bearing onto the case using the J 44420 and the J 8092. 3. Install the differential assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Service and Repair > All Except 9.75 Inch Axle > Page 7283 Carrier Bearings: Service and Repair 9.75 Inch Axle Differential Side Bearings Replacement (9.75 Inch Axle) ^ Tools Required J 22888-D Side Bearing Remover Kit - J 24430 Differential Side Bearing Installer - J 36597 Side Bearing Puller Pilot - 9.25 inch - J 45711 Differential Side Bearing Remover - Dana 248 - J 45900 Differential Side Bearing Installer - Dana Axles - J 8092 Universal Driver Handle - 3/4 in - 10 Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the differential side bearing by performing the following steps: 1. Install the J 45711 (2) and the J 36597 (1) as shown. 2. Remove the differential side bearing using the J 45711 and a hydraulic press. 4. Important: Mark the inboard shims left or right. Remove the inboard shims. Installation Procedure 1. Determine the shim thickness and preload for the differential assembly. 2. Install the differential side bearing by doing the following: 1. In order to protect the differential case, install the J 8107-3 in the case on the side opposite of the bearing installation. 2. Install the inboard shims. 3. Install the differential side bearing. 4. Install the J 24430 or the J 45900 (2) and the J 8092 (1) over the differential side bearing. 5. Drive the differential side bearing into position using the J 24430 or the J 45900 and the J 8092. 6. Install the differential assembly. 3. Fill the axle with lubricant. Use the proper fluid. 4. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Axle Housing Cover and Gasket Replacement Differential Axle Housing: Service and Repair Rear Axle Housing Cover and Gasket Replacement Rear Axle Housing Cover and Gasket Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Drain the rear axle. 3. Remove the rear axle housing cover bolts (1).Discard the rear axle housing cover bolts. 4. Remove the rear axle housing cover (2) from the axle housing. 1. Catch the oil in a drain pan. 2. Remove any gasket material from the rear axle housing and/or the rear axle housing cover. Installation Procedure 1. Install the rear axle housing cover (2) and a new gasket. Notice: Refer to Fastener Notice in Service Precautions. 2. Important: Do not reuse the rear axle housing cover bolts. Install the new rear axle housing cover bolts (1). ^ Tighten the rear axle housing cover bolts in a crosswise pattern to 40 Nm (30 ft. lbs.). 3. Fill the rear axle. Use the proper fluid. 4. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Rear Axle Housing Cover and Gasket Replacement > Page 7288 Differential Axle Housing: Service and Repair Rear Axle Housing Replacement Rear Axle Housing Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Drain the axle lubricant. 3. Remove the rear axle assembly. 4. Remove the brake caliper brackets. 5. For the 8.6 inch and 9.5 inch axles, remove the brake rotors. 6. For the 10.5 inch and 11.5 inch axles, remove the hub and rotor assembly. 7. Remove the rear axle cover housing and gasket. 8. Remove the axle shafts. 9. Remove the brake backing plates. 10. For the 8.6 inch and 9.5 inch axles, remove the rear axle shaft oil seal and the bearing. 11. Remove the differential assembly. 12. Remove the drive pinion shaft yoke and the oil seal. 13. Remove the drive pinion and the inner pinion bearing. 14. Remove the pinion bearing cups. Installation Procedure 1. Install the pinion bearing cups. 2. Install the outer pinion bearing into the axle housing. 3. Install the drive pinion oil seal. 4. Determine the selective shim thickness for the drive pinion. 5. Install the selective shim onto the drive pinion. 6. Install the inner pinion bearing onto the drive pinion. 7. Install the drive pinion. 8. Install the pinion yoke. 9. Install the differential assembly. 10. Adjust the differential side bearing preload. 11. Adjust the drive pinion to ring gear backlash. 12. Perform a gear tooth contact pattern check. 13. Install the brake backing plates. 14. For the 10.5 inch and 11.5 inch axles, install the hub/rotor assembly. 15. For the 8.6 inch and 9.5 inch axles, install the rear axle shaft bearing and the oil seal. 16. Install the axle shafts. 17. Install the rear axle housing cover and gasket. 18. For the 8.6 inch and 9.5 inch axles, install the brake rotors. 19. Install the brake caliper brackets. 20. Install the rear axle assembly. 21. Fill the axle with lubricant. Use the proper fluid. 22. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Front Drive Axle Lubrication Update Fluid - Differential: Technical Service Bulletins Drivetrain - Front Drive Axle Lubrication Update Bulletin No.: 05-00-90-010 Date: December 07, 2005 SERVICE MANUAL UPDATE Subject: Revised Front Drive Axle Carrier Lubricant Information Models: 1999-2005 Light Duty Trucks 2003-2005 HUMMER H2 2005 Saab 9-7X with Four-Wheel or All-Wheel Drive and Separate Front Drive Axle Carriers This bulletin is being issued to revise the front drive axle carrier lubricant specification in the Maintenance and Lubrication and the Front Drive Axle sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. This information also updates the information found in the Owner Manual. Important: Front drive axle carriers do not require periodic lubricant replacement. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Front Drive Axle Lubrication Update > Page 7293 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Front Drive Axle Lubrication Update > Page 7294 Fluid - Differential: Technical Service Bulletins Drivetrain - Synthetic Fluid Usage in Front Differential File In Section: 04 - Driveline Axle Bulletin No.: 03-04-19-001B Date: September, 2004 INFORMATION Subject: Use of Synthetic Front Axle Lubricant for 4WD Vehicles Sold in Cold Weather Climates Models: 2002-2004 Chevrolet Avalanche 2500, Silverado 2500/3500, Suburban 2500 2002-2003 Chevrolet Silverado 1500HD 2002-2004 GMC Sierra 2500/3500, Yukon XL 2500 2002-2003 GMC Sierra 1500HD with Four-Wheel Drive and 9.25" Front Axle Assemblies and Built Prior to April 1, 2004 This bulletin is being revised to update vehicle applications, part numbers and fluid fill information. Please discard Corporate Bulletin Number 03-04-19-001A (Section 04 - Driveline/Axle). Important: This bulletin is intended for vehicles sold in very cold weather climates, especially those in Alaska and certain regions of Canada. Important: This bulletin DOES NOT apply to vehicles built after April 1, 2004. Vehicles referenced above that were built after April 1, 2004 were manufactured with front axles containing synthetic axle lubricant and do not need to have the front axle fluid inspected or changed. Front axles in the above-listed vehicles built before April 1, 2004 are manufactured with mineral-oil base axle fluid. Because of the 9.25" front axle assembly's internal design characteristics, there may be insufficient lubrication flow at very low ambient temperatures (-24°C (-12°F) or below). This may contribute to premature pinion bearing wear if a vehicle is driven extensively in very low ambient temperatures. Important: Please be certain that PDI personnel know to perform the drain/refill procedure all year round (not just in the cold weather months). New vehicles that are expected to operate extensively in 4WD in temperatures below -24°C (-12°F) should have their front axle fluid drained and refilled with synthetic axle lubricant during PDI or before delivery to the first retail customer. Follow the Front Drive Axle Lubricant Replacement procedure found in the Service Manual. It is not necessary to flush the front axle assembly. Use Synthetic Axle Lubricant, P/N 12378261 or P/N 89021677 (Canadian P/N 10953455 or P/N 89021678). Each of these part numbers is the same axle lubricant, with differences in packaging only. Fill to a level between 6 and 9 mm (0.25 in to 0.375 in) below the bottom of the fill plug. For vehicles that have the axle lubricant changed, the front axle vent hose connector assembly will need to be inspected. Important: Front axle assemblies with a vent hose connector assembly that is white in color do not need to be changed. If the vent hose connector is black in color, it will need to be changed so that the 0-ring seal is compatible with the synthetic lubricant Install vent connector, P/N 12479390. Follow the Front Drive Axle Vent Hose Connector Replacement procedure in the Service Manual. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Front Drive Axle Lubrication Update > Page 7295 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Fluid Capacity Differential Oil Capacity Front Drive Axle (8.25") ....................................................................................................................... ............................................ 1.43 liters (1.51 quarts) Front Drive Axle (9.25") .................................... ............................................................................................................................... 1.73 liters (1.83 quarts) Rear Drive Axle (8.6") ............................................................................................................. ......................................................... 2.03 liters (2.15 quarts) Rear Drive Axle (9.5") .......................... ............................................................................................................................................ 2.60 liters (2.75 quarts) Rear Drive Axle (9.75") .................................................................................................. .................................................................. 2.84 liters (3.00 quarts) Rear Drive Axle (10.5") ............... ..................................................................................................................................................... 2.60 liters (2.75 quarts) Rear Drive Axle (11.5") .......................................................................................... .......................................................................... 3.00 liters (3.17 quarts) Lubricant Level - 8.6 Inch Axle Differential Oil Capacity Capacity .................................................................................................................................................... 15-40 mm from bottom edge of the fill plug hole Lubricant Level - 9.5, 10.5 Inch Axles Differential Oil Capacity Capacity ............................................................................................................................................... ........................ 0-10 mm below the fill plug opening Lubricant Level - 9.75 Inch Axel Differential Oil Capacity Capacity ............................................................................................................................................... .......................... 0-4 mm below the fill plug opening Lubricant Level - 11.5 Inch Axle Differential Oil Capacity Capacity ............................................................................................................................................... ...................... 17-21 mm below the fill plug opening Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 7298 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Differential Fluid Type Front 4WD Grade ................................................................................................................................ ............................................................................................. GL-5 Viscosity ....................................... .............................................................................................................................................................. .............. 80W-90 Front AWD Grade ................................................................................................... .................................................................................................................... Synthetic Viscosity .......... .............................................................................................................................................................. ........................................... 75W-90 Rear Grade ................................................................................ ....................................................................................................................................... Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 Rear (Steerable) Grade ................................... .............................................................................................................................................................. ...................... Synthetic Viscosity ........................................................................................................ ........................................................................................................... 75W-90 Front Differential Differential Fluid Type The content of this article reflects the changes identified in TSB number 05-00-90-010 dated December 07, 2005. 1999-2004 7.25 Inch (Blazer, Jimmy, S-10, Sonoma, Astro, Safari) Grade ........................................ .............................................................................................................................................................. ....................... GL-5 Viscosity ............................................................................................................. ...................................................................................................... 80W-90 2002-2005 7.25 Inch (Trailblazer, Envoy, Bravada, Rainier Grade ....................................................................................... ................................................................................................................................ Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 8.25 Inch With Selectable 4WD Grade ............ .............................................................................................................................................................. ................................................... GL-5 Viscosity ................................................................................. .................................................................................................................................. 80W-90 8.25 Inch With AWD Grade ......................................................................................................................... .............................................................................................. Synthetic Viscosity ................................ .............................................................................................................................................................. ..................... 75W-90 1999-2001 9.25 Inch Grade ............................................................................. ................................................................................................................................................ GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 2002-2005 9.25 Inch Grade ............................. .............................................................................................................................................................. ............................ Synthetic Viscosity .................................................................................................. ................................................................................................................. 75W-90 Front Drive Axle Differential Fluid Type The content of this article reflects the changes identified in TSB number 05-00-90-010 dated December 07, 2005. 1999-2004 7.25 Inch (Blazer, Jimmy, S-10, Sonoma, Astro, Safari) Grade ........................................ .............................................................................................................................................................. ....................... GL-5 Viscosity ............................................................................................................. ...................................................................................................... 80W-90 2002-2005 7.25 Inch (Trailblazer, Envoy, Bravada, Rainier Grade ....................................................................................... ................................................................................................................................ Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 8.25 Inch With Selectable 4WD Grade ............ .............................................................................................................................................................. ................................................... GL-5 Viscosity ................................................................................. .................................................................................................................................. 80W-90 8.25 Inch With AWD Grade ......................................................................................................................... .............................................................................................. Synthetic Viscosity ................................ .............................................................................................................................................................. ..................... 75W-90 1999-2001 9.25 Inch Grade ............................................................................. ................................................................................................................................................ GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 2002-2005 9.25 Inch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 7299 Grade ................................................................................................................................................... .................................................................... Synthetic Viscosity .......................................................... ......................................................................................................................................................... 75W-90 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle Fluid - Differential: Service and Repair Front Drive Axle Lubricant Level Inspection Lubricant Level Inspection - Front Drive Axle 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the front axle for leaks. Repair as necessary. 4. Clean the area around the front axle fill plug. 5. Remove the front axle fill plug (1). 6. Inspect the oil level. ^ For the 8.25 inch axle, the oil level should be between 12-16 mm (0.50-0.625 inch) below the fill plug opening. ^ For the 9.25 inch axle, the oil level should be between 0-6 mm (0-0.25 inch) below the fill plug opening. 7. If the level is low, add oil until the level is between 12-16 mm (0.50-0.625 inch) for the 8.25 inch axle or 0-6 mm (0-0.25 inch) for the 9.25 inch axle. Use the correct fluid. 8. Install the fill plug. ^ Tighten the plug to 33 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 9. Lower the vehicle. Lubricant Replacement Lubricant Replacement - Front Drive Axle Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the front differential carrier shield, if equipped. 3. Clean the area around the front axle fill plug and the drain plug. 4. Remove the fill plug. 5. Remove the drain plug. 6. Drain the fluid from the front differential carrier assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle > Page 7302 Installation Procedure 1. Install the drain plug. ^ Tighten the drain plug to 33 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Fill the differential carrier assembly with axle lubricant. Use the correct fluid. 3. Install the fill plug. ^ Tighten the fill plug to 33 Nm (24 ft. lbs.). 4. Install the front differential carrier shield, if equipped. 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle > Page 7303 Fluid - Differential: Service and Repair Rear Drive Axle 8.6 Inch Axle Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Fabricate a dipstick from a pipe cleaner or similar item. Form the pipe cleaner into an "L". 7. Insert the pipe cleaner into the fill plug opening with the stem facing down. 8. Remove the pipe cleaner and measure the distance from the bend in the pipe cleaner to the lubricant level. The distance between the bend and the lubricant level should be 15-40 mm (0.6-1.6 inch). 9. If the measurement is greater than 40 mm (1.6 inch), add lubricant until the level is between 15-40 mm (0.6-1.6 inch) from the bottom edge of the fill plug hole. Use the proper fluid. 10. Notice: Refer to Fastener Notice in Service Precautions. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 11. Lower the vehicle. 9.5, 10.5 Inch Axle Lubricant Level Inspection - Rear Drive Axle (9.5, 10.5 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting in General Information. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0-10 mm (0-0.4 inch) below the fill plug opening. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle > Page 7304 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. 8. Notice: Refer to Fastener Notice in Service Precautions. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 9. Lower the vehicle. 9.75 Inch Axle Lubricant Level Inspection - Rear Drive Axle (9.75 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Ensure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0-4 mm (0-0.16 inch) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. 8. Notice: Refer to Fastener Notice in Service Precautions. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 21 Nm (15 ft. lbs.). 9. Lower the vehicle. 11.5 Inch Axle Lubricant Level Inspection - Rear Drive Axle (11.5 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug and the seal. 6. Inspect the lubricant level. The lubricant level should be between 17-21 mm (0.6-0.8 inch) below the fill plug opening. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle > Page 7305 7. If the level is low, add lubricant until the level is between 17-21 mm (0.6-0.8 inch) below the fill plug opening. Use the proper fluid. 8. Notice: Refer to Fastener Notice in Service Precautions. Install the rear axle fill plug and gasket. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 9. Lower the vehicle. 8.6 Inch Axle Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the rear axle fill plug. 3. Remove the rear axle housing cover bolts (1). Discard the rear axle housing cover bolts. 4. Carefully remove the rear axle housing cover (2) and drain the lubricant into a suitable container. 5. Remove any gasket material from the rear axle housing and/or the rear axle housing cover. 6. Inspect the bottom of the rear axle housing for excessive metal particle accumulation. This accumulation is an indication of extreme wear. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle > Page 7306 1. Install a new gasket and the rear axle housing cover (2). 2. Notice: Refer to Fastener Notice in Service Precautions. Important: Do not reuse the rear axle housing cover bolts. Install the new rear axle housing cover bolts (1). ^ Tighten the bolts to 40 Nm (30 ft. lbs.). 3. Fill the rear axle. Use the proper fluid. 4. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 5. Lower the vehicle. 9.75 Inch Axle Lubricant Replacement - Rear Drive Axle (9.75 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the rear axle fill plug. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle > Page 7307 3. Remove the rear axle drain plug. 4. Drain the lubricant into a suitable container. 5. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 6. Clean the drain plug. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the rear axle drain plug. ^ Tighten the rear axle drain plug to 27 Nm (20 ft. lbs.). 2. Fill the rear axle. Use the proper fluid. 3. Install the rear axle fill plug. ^ Tighten the rear axle fill plug to 21 Nm (15 ft. lbs.). 4. Lower the vehicle. 9.5, 10.5, and 11.5 Inch Axles Lubricant Replacement - Rear Drive Axle (9.5, 10.5, and 11.5 Inch Axles) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle > Page 7308 2. For the 9.5 inch and the 10.5 inch axles, remove the rear axle fill plug. 3. For the 11.5 inch axle, remove the fill plug. 4. Remove the rear axle drain plug. 5. Drain the lubricant into a suitable container. 6. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 7. Clean the drain plug. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the rear axle drain plug. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Front Drive Axle > Page 7309 ^ Tighten the rear axle drain plug to 33 Nm (24 ft. lbs.). 2. Fill the rear axle. Use the proper fluid. 3. For the 9.5 inch and the 10.5 inch axles, install the rear axle fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 4. For the 11.5 inch axle, install the seal and the fill plug. ^ Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.6, 9.5, 11.5 Inch Axles Pinion Bearing: Service and Repair 8.6, 9.5, 11.5 Inch Axles Drive Pinion Bearings Replacement (8.6, 9.5, 11.5 Inch Axles) ^ Tools Required J 7818 Inner Bearing Race Installer, 9.5 inch axle - J 8092 Driver Handle 3⁄4 in - 10 - J 8608 Rear Pinion Bearing Race Installer, 8.6 inch, 11.5 inch axle - J 8614-01 Flange and Pulley Holding Tool - J 22306 Pinion Cup Bearing Installer - Rear, 9.5 inch axle - J 22388 Rear Axle Pinion Oil Seal Installer, 8.6 inch, 9.5 inch axle - J 22912-01 Split Plate Bearing Puller - J 24433 Pinion Cone and Side Bearing Installer, 8.6 inch axle - J 36614 Inner Pinion Bearing Installer, 9.5 inch axle - J 44412 Pinion Bearing Installer, 11.5 inch axle - J 44414 Rear Axle Pinion Oil Seal Installer, 11.5 inch axle - J 44417 Rear Pinion Bearing Race Installer, 11.5 inch axle - J 45871 Pinion Bearing Remover - J 45900 Pinion Bearing Cup Installer, 8.6 in axle Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the drive pinion from the axle. 4. For the 8.6 inch axle, install the J 45871 (1) around the pinion bearing and the J 22912-01 (2) in the inverted position around the J 45871. 5. Press the bearing off of the pinion using the J 45871 and the J 22912-01. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.6, 9.5, 11.5 Inch Axles > Page 7314 6. For the 9.5 inch and 11.5 inch axles, press the bearing off of the pinion using the J 22912-01. 7. Remove the shim. 8. Remove the outer pinion bearing cup from the axle housing using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly. 9. Remove the inner pinion bearing cup from the axle housing using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.6, 9.5, 11.5 Inch Axles > Page 7315 1. Install the outer pinion bearing cup using the J 8611-01 , 8.6 inch axle, or the J 7818, 9.5 inch axle, or the J 8608 (11.5 inch axle) (2) and the J 8092 (1). 2. Install the inner pinion bearing cup using the J 45900, 8.6 inch axle, or the J 22306, 9.5 inch axle, or the J 44417, 11.5 inch axle (2) and the J 8092 (1). 3. Determine the selective shim thickness for the pinion. 4. Install the selective shim between the inner pinion bearing and the shoulder on the gear. 5. Install the inner pinion bearing using the J 24433, 8.6 inch axle, or the J 36614, 9.5 inch axle, or the J 44412, 11.5 inch axle. Press the bearing on until the cone seats on the pinion shim. 6. Install a new collapsible spacer. 7. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. 8. Install the outer pinion bearing into the axle housing. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.6, 9.5, 11.5 Inch Axles > Page 7316 9. Install a new pinion oil seal using the J 22388, 8.6 inch, 9.5 inch axles, or the J 44414, 11.5 inch axle. 10. Install the pinion into the axle housing. 11. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke. 12. Install the pinion yoke. Align the marks made during removal. 13. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 14. Install the washer and a new pinion nut. 15. Install the J 8614-01 onto the pinion yoke as shown. 16. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. ^ Tighten the pinion nut while holding the J 8614-01. ^ Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.6, 9.5, 11.5 Inch Axles > Page 7317 17. Measure the rotating torque of the pinion using an inch-pound torque wrench. The rotating torque of the pinion should be between 1.0-2.3 Nm (10-20 inch lbs.) for used bearings, or 1.7-3.4 Nm (15-30 inch lbs.) for new bearings. 18. If the rotating torque measurement is below 1.0 Nm (10 inch lbs.) for used bearings, or 1.7 Nm (15 inch lbs.) for new bearings, continue to tighten the pinion nut. ^ Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is between 1.0-2.3 Nm (10-20 inch lbs.) for used bearings, or 1.7-3.4 Nm (15-30 inch lbs.) for new bearings. 19. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Inspect the rotating torque and adjust if necessary. 20. Install the differential assembly. 21. Fill the axle with lubricant. Use the proper fluid. 22. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.6, 9.5, 11.5 Inch Axles > Page 7318 Pinion Bearing: Service and Repair 9.75 Inch Axle Drive Pinion Bearings Replacement (9.75 Inch Axle) ^ Tools Required J 22536 Pinion Driver - J 22912-01 Split-Plate Bearing Puller - J 42176 Universal Driver Handle - Non-Threaded - J 45703 Pinion Bearing Race Remover - Dana 248 - J 45704 Pinion Bearing Race Installer - Dana 248 - J 45705 Pinion Bearing Race Remover - Dana 248/267 - J 7818 Inner Bearing Race Installer - J 8092 Universal Drive Handle - 3⁄4 in - 10 Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the pinion yoke and the pinion oil seal. 4. Remove the thrust washer. 5. Install the J 22536 as shown. Ensure that the J 22536 is firmly seated on the pinion. 6. Drive the pinion out using the J 22536 and a hammer.Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing. 7. Remove the pinion preload shims from the drive pinion and set aside. 8. Remove the inner pinion bearing cup and the oil deflector using the J 45703 (2) and the J 42176 (1). 9. Remove the outer pinion bearing cup using the J 45705 and the J 42176. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.6, 9.5, 11.5 Inch Axles > Page 7319 10. Remove the inner pinion bearing using the J 22912-01 and a hydraulic press. 11. Remove the pinion position shim. Installation Procedure 1. Install the oil deflector into the inner pinion cup bore. 2. Install the inner pinion bearing cup using the J 45704 (2) and the J 8092 (1). 3. Install the outer pinion bearing cup using the J 7818 (2) and the J 8092 (1). 4. Determine the pinion position shim thickness and the pinion preload shim thickness for the drive pinion. 5. Install the differential assembly. 6. Fill the axle with lubricant. Use the proper fluid. 7. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.6, 9.5, 11.5 Inch Axles > Page 7320 Pinion Bearing: Service and Repair 10.5 Inch Axle Drive Pinion Bearings Replacement (10.5 Inch Axle) ^ Tools Required J 22388 Pinion Oil Seal Installer - Rear - J 22761 Differential Side Bearing Installer - J 22912-01 Split Plate Bearing Puller - J 24433 Pinion Cone and Side Bearing Installer - J 37624 Pi non Bearing Installer - J 8092 Universal Driver Handle - 3⁄4 in - 10 - J 8608 Rear Pinion Bearing Installer - J 8614-01 Flange and Pulley Holding Tool Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the pinion gear bearing retainer. 4. Remove the pinion yoke and the oil seal. 5. Remove the outer pinion bearing. 6. Remove the pinion. 7. Remove the collapsible spacer. 8. Remove the inner pinion bearing from the pinion using the J 22912-01 and a hydraulic press. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.6, 9.5, 11.5 Inch Axles > Page 7321 9. Remove the outer pinion bearing cup using a hammer and a brass drift in the slots provided.Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 10. Remove the inner pinion bearing cup using a hammer and a brass drift in the slots provided.Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 11. Remove the pinion gear pilot bearing using a brass drift and a hammer. Installation Procedure 1. Install the pinion gear pilot bearing using the J 22761. 2. Install the inner pinion bearing cup into the pinion gear bearing retainer using the J 37624 (2) and the J 8092 (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.6, 9.5, 11.5 Inch Axles > Page 7322 3. Install the outer pinion bearing cup into the pinion gear bearing retainer using the J 8608 (2) and the J 8092 (1). 4. Install the inner pinion bearing using the J 24433. Press the bearing on until the cone seats on the pinion. 5. Install a new collapsible spacer. 6. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. 7. Install the outer pinion bearing into the pinion bearing retainer. 8. Install a new pinion oil seal using the J 22388. 9. Install the pinion into the pinion gear bearing retainer. 10. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke. 11. Install the pinion yoke. Align the marks made during removal. 12. Notice: Refer to Pinion Flange/Yoke Installation Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > 8.6, 9.5, 11.5 Inch Axles > Page 7323 Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few threads show through the yoke. 13. Install the washer and a new pinion nut. 14. Install the J 8614-01 onto the pinion yoke. 15. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. ^ Tighten the pinion nut while holding the J 8614-01. ^ Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. 16. Remove the J 8614-01. 17. Important: Do not apply sealant to the pinion gear bearing retainer at this time. Install the original shim to the pinion bearing retainer. If the original shim is not available, install a 0.41 mm (0.016 inch) shim to build pinion depth. 18. Install the pinion gear bearing retainer to the axle housing. 19. Install the pinion bearing retainer bolts. ^ Tighten the pinion gear retainer bolts to 88 Nm (65 ft. lbs.). 20. Measure the rotating torque of the pinion using an inch-pound torque wrench. The rotating torque of the pinion should be between 1.0-2.3 Nm (10-20 inch lbs.) for used bearings, or 1.7-3.4 Nm (15-30 inch lbs.) for new bearings. 21. If the rotating torque measurement is below 1.0 Nm (10 inch lbs.) for used bearings, or 1.7 Nm (15 inch lbs.) for new bearings, install the J 8614-01 and continue to tighten the pinion nut. ^ Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is between 1.0-2.3 Nm (10-20 inch lbs.) for used bearings, or 1.7-3.4 Nm (15-30 inch lbs.) for new bearings. 22. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 23. Install the differential assembly. 24. Adjust the differential side bearing preload. 25. Determine the selective shim thickness for the drive pinion. 26. Adjust the backlash. 27. Fill the axle with lubricant. Use the proper fluid. 28. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle Pinion Flange: Service and Repair Front Drive Axle Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement - Front ^ Tools Required J 8614-01 Flange and Pulley Holding Tool - J 36366 Pinion Oil Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Remove the brake calipers. 4. Remove the differential carrier assembly shield, if equipped. 5. Reference mark the relationship of the propeller shaft to the front axle pinion yoke. 6. Remove the yoke retainer bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1). 7. Disconnect the propeller shaft universal joint (2) from the front axle pinion yoke (1). Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Notice: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 8. Support the propeller shaft and move out of the way as necessary. 9. Measure the torque required in order to rotate the pinion. Use an inch-pound torque wrench. Record the torque value for reassembly. This will give the combined preload for the following components: ^ The pinion bearings ^ The pinion seal ^ The carrier bearings Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 7328 ^ The axle bearings ^ The axle seals 10. Scribe an alignment line between the pinion shaft and the pinion yoke. 11. Install the J 8614-01 onto the pinion as shown. 12. Remove the pinion nut while holding the J 8614-01. 13. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 14. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). 15. Remove the oil seal using a suitable seal removal tool. Important: Carefully remove the oil seal from the bore. Do not distort or scratch the aluminum case. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 7329 1. Install the oil seal by doing the following: 1. Position the oil seal over the seal bore. 2. Install the J 36366 over the oil seal. 3. Strike the J 36366 with a hammer until the seal flange seats on the axle housing surface. 2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the drive pinion yoke. 3. Install the pinion yoke. Align the reference marks made during removal. 4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. Notice: Refer to Pinion Flange/Yoke Installation Notice in Service Precautions. 5. Install the washer and a new pinion nut. 6. Install the J 8614-01 onto the pinion yoke as shown. 7. Tighten the pinion nut while holding the J 8614-01. ^ Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 8. Measure the rotating torque of the pinion using an inch-pound torque wrench.Compare the measurement with the rotating torque recorded earlier. ^ Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 0.40-0.57 Nm (3-5 inch lbs.) greater than the torque recorded during removal. 9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 7330 10. Install the propeller shaft universal joint (2) to the pinion yoke (1).Align the reference marks made during removal. 11. Install the yoke retainers (7) and the yoke retainer bolts (6) to the pinion yoke (1). ^ Tighten the yoke retainer bolts to 25 Nm (18 ft. lbs.). 12. Inspect the axle lubricant level, and add, if necessary. 13. Install the differential carrier assembly shield, if equipped. 14. Install the brake calipers. 15. Install the tire and wheel assemblies. 16. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 7331 Pinion Flange: Service and Repair Rear Drive Axle All Except 9.75 Inch Axle Drive Pinion Flange/Yoke and/or Oil Seal Replacement (All Except 9.75 Inch Axle) ^ Tools Required J 8614-01 Flange/Pulley Holding Tool - J 22388 Rear Axle Pinion Oil Seal Installer - Rear (8.6 inch, 9.5 inch axle) - J 44414 Rear Axle Pinion Oil Seal Installer (10.5 inch, 11.5 inch axle) Removal Procedure 1. Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies (8.6 inch, 9.5 inch axles). 3. Remove the rear brake calipers (8.6 inch, 9.5 inch axles). 4. Remove the brake rotors (8.6 inch, 9.5 inch axles). 5. Remove the axle shafts (10.5 inch, 11.5 inch axle). 6. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 7. Disconnect the propeller shaft from the axle. Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Support the propeller shaft as necessary. 8. Measure the amount of torque required to rotate the pinion. Use an inch-pound torque wrench. Record this measurement for reassembly. This will give the combined preload for the following components: ^ The pinion bearings ^ The pinion pilot bearing (10.5 inch axle) ^ The pinion oil seal ^ The differential case bearings ^ The axle bearings (8.6 inch, 9.5 inch axles) ^ The axle seals (8.6 inch, 9.5 inch axles) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 7332 9. Place an alignment mark between the pinion and the pinion yoke. 10. Install the J 8614-01 as shown. 11. Remove the pinion nut while holding the J 8614-01. 12. Remove the washer. 13. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 14. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). Use a container in order to retrieve the lubricant. 15. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing. Installation Procedure 1. Install a new pinion oil seal using the J 22388 (8.6 inch, 9.5 inch axles) or the J 44414 (10.5 inch, 11.5 inch axle). 2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the pinion yoke. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 7333 3. Install the pinion yoke.Align the marks made during removal. 4. Notice: Refer to Pinion Flange/Yoke Installation Notice in Service Precautions. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 5. Install the washer and a new pinion nut. 6. Install the J 8614-01 onto the pinion yoke as shown. 7. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. ^ Tighten the pinion nut while holding the J 8614-01. ^ Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. 8. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal. ^ Tighten the nut in small increments, as needed, until the rotating torque is 0.40-0.57 Nm (3-5 inch lbs.) greater than the rotating torque recorded during removal. 9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 10. Install the propeller shaft (3) to the pinion yoke (4). Align the reference marks made during removal. 11. Install the propeller shaft yoke retaining clamps and the bolts. ^ Tighten the propeller shaft yoke retaining clamp bolts to 25 Nm (18 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 7334 12. Install the axle shafts (10.5 inch, 11.5 inch axle). 13. Install the brake rotors (8.6 inch, 9.5 inch axles). 14. Install the brake calipers (8.6 inch, 9.5 inch axles). 15. Install the tire and wheel assemblies. 16. Inspect and add axle lubricant to the axle housing, if necessary. 17. Lower the vehicle. 9.75 Inch Axle Drive Pinion Flange/Yoke and/or Oil Seal Replacement (9.75 Inch Axle) ^ Tools Required J 8614-01 Flange and Pulley Holding Tool - J 45710 Pinion Bearing Oil Seal Installer Removal Procedure 1. Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the propeller shaft from the rear axle pinion yoke. 3. Place an alignment mark between the pinion and the pinion yoke. 4. Install the J 8614-01 as shown. 5. Remove the pinion nut while holding the J 8614-01. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 7335 6. Remove the washer. 7. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 8. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1).Use a container in order to retrieve the lubricant. 9. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the axle housing. Installation Procedure 1. Apply a light coat of axle lubricant, GM P/N 12378557 or equivalent meeting GM Specification 9986207, to the lip of the pinion seal. 2. Install the new seal using the J 45710. 3. Install the pinion yoke. 4. Notice: Refer to Pinion Flange/Yoke Installation Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 7336 Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 5. Install the washer. 6. Install the new pinion nut 7. Install the J 8614-01 onto the pinion yoke as shown. 8. Notice: Refer to Fastener Notice in Service Precautions. Tighten the pinion nut while holding the J 8614-01. ^ Tighten the pinion nut to 370 Nm (273 ft. lbs.). 9. Install the propeller shaft to the rear axle pinion yoke. 10. Inspect and add axle lubricant to the axle housing, if necessary. 11. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement Pinion Gear: Service and Repair Drive Pinion Housing and/or Seal Replacement Drive Pinion Housing and/or Seal Replacement ^ Tools Required J 44414 Pinion Seal Installer - J 22912-01 Bearing Puller - J 24433 Pinion Cone and Side Bearing Installer - J 37624 Pinion Bearing Installer - J 8092 Driver Handle - J 8608 Rear Pinion Bearing Race Installer - J 8614-01 Flange/Pulley Holding Tool Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 2. Drain the axle lubricant. 3. Remove the axle shafts. 4. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 5. Disconnect the propeller shaft from the axle. Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Support the propeller shaft as necessary. 6. Measure the amount of torque required to rotate the pinion and the ring gear. Use an inch-pound torque wrench. Record this measurement for reassembly. This will give the combined preload for the following components: ^ The pinion bearings ^ The pinion pilot bearing ^ The pinion oil seal ^ The differential case bearings Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 7341 7. Place an alignment mark between the pinion and the pinion yoke. 8. Remove the pinion gear bearing retainer bolts. 9. Remove the pinion gear bearing retainer and the pinion. 10. Remove the selective shim. 11. Measure the amount of torque required to rotate the pinion. Use an inch-pound torque wrench. Record this measurement for reassembly. 12. Install the J 8614-01 as shown. 13. Remove the pinion nut while holding the J 8614-01. 14. Remove the washer. 15. Install the J 8614-2 (2) and the J 8614-3 (1) into the J 8614-01 (3) as shown. 16. Remove the pinion yoke by turning the J 8614-3 (1) clockwise while holding the J 8614-01 (3). 17. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing. 18. Remove the outer pinion bearing. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 7342 19. Remove the pinion. 20. Remove the collapsible spacer. 21. Remove the inner pinion bearing from the pinion using the J 22912-01 and a hydraulic press. 22. Remove the outer pinion bearing cup using a hammer and a brass drift in the slots provided.Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 23. Remove the inner pinion bearing cup using a hammer and a brass drift in the slots provided.Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 7343 1. Install the inner pinion bearing cup into the pinion gear bearing retainer using the J 37624 (2) and the J 8092 (1). 2. Install the outer pinion bearing cup into the pinion gear bearing retainer using the J 8608 (2) and the J 8092 (1). 3. Install the inner pinion bearing using the J 24433.Press the bearing on until the cone seats on the pinion. 4. Install a new collapsible spacer. 5. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. 6. Install the pinion into the pinion gear bearing retainer. 7. Install the outer pinion bearing onto the pinion. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 7344 8. Install a new pinion oil seal using the J 44414. 9. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke. 10. Install the pinion yoke. Align the marks made during removal. 11. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. Notice: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft. 12. Install the washer and a new pinion nut. 13. Install the J 8614-01 onto the pinion yoke as shown. 14. Tighten the pinion nut while holding the J 8614-01. ^ Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 15. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal. ^ Tighten the nut in small increments, as needed, until the rotating torque is 0.40-0.57 Nm (3-5 inch lbs.) greater than the rotating torque recorded during removal. 16. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 7345 17. Determine the selective shim thickness for the pinion gear bearing retainer. 18. Apply sealant, GM P/N 1052942 (Canadian P/N 10953466) or equivalent, to sealing surface of the pinion gear bearing retainer. 19. Install the selective shim.Align the tab on the shim with the unmachined surface of the pinion gear bearing retainer. 20. Apply sealant, GM P/N 1052942 (Canadian P/N 10953466) or equivalent, to surface of the selective shim. 21. Install the pinion gear bearing retainer. 22. Install the pinion gear bearing retainer bolts. ^ Tighten the pinion gear bearing retainer bolts to 88 Nm (65 ft. lbs.). 23. Measure the rotating torque of the pinion and the ring gear. Compare this measurement with the rotating torque recorded during removal. The rotating torque of the pinion and the ring gear should be between 3.9-6.2 Nm (30-55 inch lbs.) for new bearings or 2.8-5.6 Nm (25-50 inch lbs.) for used bearings. 24. If the rotating torque of the pinion and the ring gear is not within specifications, adjust the preload of the pinion or the differential side bearings as necessary. 25. Install the propeller shaft (3) to the pinion yoke (4).Align the reference marks made during removal. 26. Install the propeller shaft yoke retaining clamps and the bolts. ^ Tighten the propeller shaft yoke retaining clamp bolts to 25 Nm (18 ft. lbs.). 27. Install the axle shafts. 28. Fill the axle with axle lubricant. 29. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 7346 Pinion Gear: Service and Repair Drive Pinion and Ring Gear Replacement 8.6 Inch, 9.5 Inch, 11.5 Inch Axles Drive Pinion and Ring Gear Replacement (8.6 Inch, 9.5 Inch, 11.5 Inch Axles) ^ Tools Required J 22536 Pinion Driver, 8.6 inch, 9.5 inch axles - J 44421 Pinion Remover, 11.5 inch axle Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the pinion yoke and the oil seal. 4. Install the J 22536 , 8.6 inch or 9.5 inch axle, or the J 44421, 11.5 inch axle as shown. Ensure that the J 22536 or the J 44421 is firmly seated on the pinion. 5. Drive the pinion out using the J 22536 or the J 44421 and a hammer. Strike the J 22536 or the J 44421 slowly. Do not let the pinion fall out of the rear axle housing. 6. Remove the collapsible spacer from the pinion. Discard the spacer. 7. Remove the pinion bearings and the cups. 8. Important: The ring gear bolts on the 8.6 inch and the 9.5 inch axles have left-hand threads. The ring gear bolts on the 11.5 inch axle have right-hand threads. Remove the gear bolts. Discard the bolts. 9. Notice: Refer to Ring Gear Removal Notice in Service Precautions. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 7347 1. Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. Install the ring gear to the differential case. 2. Important: The ring gear bolts on the 8.6 inch and the 9.5 inch axles have left-hand threads. The ring gear bolts on the 11.5 inch axle have right-hand threads. Install the new ring gear bolts.Hand start each bolt to ensure that the ring gear is properly installed to the differential case. 3. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the ring gear bolts, Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. ^ For the 8.6 inch axle, tighten the ring gear bolts in sequence to 120 Nm (89 ft. lbs.). ^ For the 9.5 inch axle, tighten the ring gear bolts in sequence to 140 Nm (103 ft. lbs.). ^ For the 11.5 inch axle, tighten the ring gear bolts in sequence to 237 Nm (175 ft. lbs.). 4. Install the pinion bearing cups. 5. Determine the selective shim thickness for the pinion gear. 6. Install the selective shim onto the pinion. 7. Install the inner pinion bearing to the pinion. 8. Install a new collapsible spacer. 9. Lubricate the pinion bearings with axle lubricant. 10. Install the outer pinion bearing into the axle housing. 11. Install the new pinion oil seal. 12. Install the pinion into the axle housing. 13. Install the pinion yoke. 14. Install the differential assembly. 15. Fill the axle with lubricant. Use the proper fluid. 16. Lower the vehicle. 9.75 Inch Axle Drive Pinion and Ring Gear Replacement (9.75 Inch Axle) ^ Tools Required J 22536 Pinion Driver Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the drive pinion yoke and the pinion oil seal. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 7348 4. Remove the thrust washer. 5. Install the J 22536 as shown. Ensure that the J 22536 is firmly seated on the pinion. 6. Drive the pinion out using the J 22536 and a hammer. Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing. 7. Remove the pinion preload shims from the drive pinion and set aside. 8. Remove the inner pinion bearing and the pinion position shim. 9. Important: The ring gear bolts have right-hand threads. Remove the ring gear bolts. Discard the bolts. 10. Notice: Refer to Ring Gear Removal Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 7349 Remove the ring gear from the differential case. Drive the gear off with a brass drift if necessary. Installation Procedure 1. Determine the pinion position shim thickness and the pinion preload shim thickness for the drive pinion gear. 2. Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. Install the ring gear to the differential case. Align the holes in the differential case to the bolts holes in the ring gear. 3. Important: The ring gear bolts have right-hand threads. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case. 4. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the new ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. ^ Tighten the new ring gear bolts to 178 Nm (131 ft. lbs.). 5. Install the differential assembly. 6. Fill the axle with lubricant. Use the proper fluid. 7. Lower the vehicle. 10.5 Inch Axle Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the pinion gear bearing retainer. 4. Remove the pinion and the pinion bearings. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 7350 5. Important: The ring gear bolts have left-hand threads. Remove the ring gear bolts. Discard the bolts. 6. Notice: Refer to Ring Gear Removal Notice in Service Precautions. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary. Installation Procedure 1. If the differential case has become separated, assemble the differential case by aligning the two arrows inside the differential case as shown. 2. Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. Install the ring gear to the differential case. 3. Important: The ring gear bolts have left-hand threads. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case. 4. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the new ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. ^ Tighten the ring gear bolts in sequence to 165 Nm (122 ft. lbs.). 5. Install the pinion and the pinion bearings. 6. Install the pinion gear bearing retainer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 7351 7. Install the differential assembly. 8. Fill the axle with lubricant. Use the proper fluid. 9. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle Seals and Gaskets: Service and Repair Front Drive Axle Inner Axle Seal and/or Bearing Replacement Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement - J 8092 Universal Driver Handle - 3/4 in - 10 - J 2619-01 Slide Hammer - J 29369-1 Bushing and Bearing Remover - J 29369-2 Bushing and Bearing Remover (2-3 inch) - J 36609 Axle Tube Bearing Installer - J 45225 Axle Seal Installer Removal Procedure 1. Raise the vehicle. 2. Drain the differential carrier assembly. 3. Remove the right side seal and/or bearing by performing the following steps: 3.1. Remove the inner axle shaft and housing assembly from the differential carrier case assembly. 3.2. Remove the clutch fork assembly components and the inner axle shaft from the inner axle shaft housing. 3.3. Install the inner axle shaft housing into a vise. - Clamp only on the mounting flange of the inner axle shaft housing. 3.4. Install the J 29369-1, 8.25 inch axle, or the J 29369-2, 9.25 inch axle, behind the inner axle shaft seal or the inner axle shaft bearing as necessary. 3.5. Install the J 2619-01 (2) to the J 29369-1 or the J 29369-2 (1). 3.6. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J 2619-01. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7356 4. If only replacing the left side seal, perform the following steps: 4.1. Place an alignment mark between the inner axle shaft and the wheel drive shaft. 4.2. Disconnect the wheel drive shaft from the inner axle shaft. 4.3. Remove the inner axle shaft using a hammer and a brass drift. 4.4. Remove the inner axle shaft seal using a suitable seal remover tool. 5. If replacing both the left side seal and bearing, perform the following steps: 5.1. Remove the differential carrier assembly. 5.2. Place the differential carrier assembly into a vise. - Clamp only on the mounting flange of the differential carrier assembly case. 5.3. Remove the inner axle shaft using a hammer and brass drift. 5.4. Install the J 29369-1, 8.25 inch axle, or the J 29369-2, 9.25 inch axle (1), behind the inner axle shaft seal or the inner axle shaft bearing as necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7357 5.5. Install the J 2619-01 (2) to the J 29369-1 or the J 2936-2. 5.6. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J 2619-01. Installation Procedure 1. Install the right side bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7358 2. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2). 3. Install the inner axle shaft into the inner axle shaft housing. - Carefully tap the inner axle shaft into place with a soft-faced mallet. 4. Install the inner axle shaft and clutch fork assembly components into the inner shaft housing. 5. Install the inner axle shaft and housing assembly to the differential carrier case assembly. 6. If both the left side bearing and seal was removed, perform the follow step. Install the left side bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2). 7. If both the left side bearing and seal was removed, perform the following step. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7359 8. If both the left side bearing and seal was removed, perform the following step. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear. - Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear. 9. If both the left side bearing and seal was removed, perform the following step. Install the front differential carrier assembly. 10. If only the left side seal was removed, perform the following step. Install the seal using the J 45225 and a soft-faced mallet. - Tap only on the center portion of the J 45225 in order to drive the seal in evenly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7360 11. If only the left side seal was removed, perform the following step. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear. - Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear. 12. If only the left side seal was removed, perform the following step. Install the wheel drive shaft to the inner axle shaft. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 13. If only the left side seal was removed, perform the following step. Install the wheel drive shaft to the inner axle shaft bolts. - Tighten the wheel drive shaft to inner axle shaft bolts to 79 Nm (58 lb ft). 14. Fill the differential carrier assembly. Use the correct fluid. 15. Lower the vehicle. Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement - Front ^ Tools Required J 8614-01 Flange and Pulley Holding Tool - J 36366 Pinion Oil Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Remove the brake calipers. 4. Remove the differential carrier assembly shield, if equipped. 5. Reference mark the relationship of the propeller shaft to the front axle pinion yoke. 6. Remove the yoke retainer bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1). 7. Disconnect the propeller shaft universal joint (2) from the front axle pinion yoke (1). Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Notice: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 8. Support the propeller shaft and move out of the way as necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7361 9. Measure the torque required in order to rotate the pinion. Use an inch-pound torque wrench. Record the torque value for reassembly. This will give the combined preload for the following components: ^ The pinion bearings ^ The pinion seal ^ The carrier bearings ^ The axle bearings ^ The axle seals 10. Scribe an alignment line between the pinion shaft and the pinion yoke. 11. Install the J 8614-01 onto the pinion as shown. 12. Remove the pinion nut while holding the J 8614-01. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7362 13. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 14. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). 15. Remove the oil seal using a suitable seal removal tool. Important: Carefully remove the oil seal from the bore. Do not distort or scratch the aluminum case. Installation Procedure 1. Install the oil seal by doing the following: 1. Position the oil seal over the seal bore. 2. Install the J 36366 over the oil seal. 3. Strike the J 36366 with a hammer until the seal flange seats on the axle housing surface. 2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the drive pinion yoke. 3. Install the pinion yoke. Align the reference marks made during removal. 4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. Notice: Refer to Pinion Flange/Yoke Installation Notice in Service Precautions. 5. Install the washer and a new pinion nut. 6. Install the J 8614-01 onto the pinion yoke as shown. 7. Tighten the pinion nut while holding the J 8614-01. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7363 ^ Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 8. Measure the rotating torque of the pinion using an inch-pound torque wrench.Compare the measurement with the rotating torque recorded earlier. ^ Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 0.40-0.57 Nm (3-5 inch lbs.) greater than the torque recorded during removal. 9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 10. Install the propeller shaft universal joint (2) to the pinion yoke (1).Align the reference marks made during removal. 11. Install the yoke retainers (7) and the yoke retainer bolts (6) to the pinion yoke (1). ^ Tighten the yoke retainer bolts to 25 Nm (18 ft. lbs.). 12. Inspect the axle lubricant level, and add, if necessary. 13. Install the differential carrier assembly shield, if equipped. 14. Install the brake calipers. 15. Install the tire and wheel assemblies. 16. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7364 Seals and Gaskets: Service and Repair Rear Drive Axle All Except 9.75 Inch Axle Drive Pinion Flange/Yoke and/or Oil Seal Replacement (All Except 9.75 Inch Axle) ^ Tools Required J 8614-01 Flange/Pulley Holding Tool - J 22388 Rear Axle Pinion Oil Seal Installer - Rear (8.6 inch, 9.5 inch axle) - J 44414 Rear Axle Pinion Oil Seal Installer (10.5 inch, 11.5 inch axle) Removal Procedure 1. Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies (8.6 inch, 9.5 inch axles). 3. Remove the rear brake calipers (8.6 inch, 9.5 inch axles). 4. Remove the brake rotors (8.6 inch, 9.5 inch axles). 5. Remove the axle shafts (10.5 inch, 11.5 inch axle). 6. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 7. Disconnect the propeller shaft from the axle. Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Support the propeller shaft as necessary. 8. Measure the amount of torque required to rotate the pinion. Use an inch-pound torque wrench. Record this measurement for reassembly. This will give the combined preload for the following components: ^ The pinion bearings ^ The pinion pilot bearing (10.5 inch axle) ^ The pinion oil seal ^ The differential case bearings ^ The axle bearings (8.6 inch, 9.5 inch axles) ^ The axle seals (8.6 inch, 9.5 inch axles) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7365 9. Place an alignment mark between the pinion and the pinion yoke. 10. Install the J 8614-01 as shown. 11. Remove the pinion nut while holding the J 8614-01. 12. Remove the washer. 13. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 14. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). Use a container in order to retrieve the lubricant. 15. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing. Installation Procedure 1. Install a new pinion oil seal using the J 22388 (8.6 inch, 9.5 inch axles) or the J 44414 (10.5 inch, 11.5 inch axle). 2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the pinion yoke. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7366 3. Install the pinion yoke.Align the marks made during removal. 4. Notice: Refer to Pinion Flange/Yoke Installation Notice in Service Precautions. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 5. Install the washer and a new pinion nut. 6. Install the J 8614-01 onto the pinion yoke as shown. 7. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. ^ Tighten the pinion nut while holding the J 8614-01. ^ Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. 8. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal. ^ Tighten the nut in small increments, as needed, until the rotating torque is 0.40-0.57 Nm (3-5 inch lbs.) greater than the rotating torque recorded during removal. 9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 10. Install the propeller shaft (3) to the pinion yoke (4). Align the reference marks made during removal. 11. Install the propeller shaft yoke retaining clamps and the bolts. ^ Tighten the propeller shaft yoke retaining clamp bolts to 25 Nm (18 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7367 12. Install the axle shafts (10.5 inch, 11.5 inch axle). 13. Install the brake rotors (8.6 inch, 9.5 inch axles). 14. Install the brake calipers (8.6 inch, 9.5 inch axles). 15. Install the tire and wheel assemblies. 16. Inspect and add axle lubricant to the axle housing, if necessary. 17. Lower the vehicle. 9.75 Inch Axle Drive Pinion Flange/Yoke and/or Oil Seal Replacement (9.75 Inch Axle) ^ Tools Required J 8614-01 Flange and Pulley Holding Tool - J 45710 Pinion Bearing Oil Seal Installer Removal Procedure 1. Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the propeller shaft from the rear axle pinion yoke. 3. Place an alignment mark between the pinion and the pinion yoke. 4. Install the J 8614-01 as shown. 5. Remove the pinion nut while holding the J 8614-01. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7368 6. Remove the washer. 7. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 8. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1).Use a container in order to retrieve the lubricant. 9. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the axle housing. Installation Procedure 1. Apply a light coat of axle lubricant, GM P/N 12378557 or equivalent meeting GM Specification 9986207, to the lip of the pinion seal. 2. Install the new seal using the J 45710. 3. Install the pinion yoke. 4. Notice: Refer to Pinion Flange/Yoke Installation Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7369 Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 5. Install the washer. 6. Install the new pinion nut 7. Install the J 8614-01 onto the pinion yoke as shown. 8. Notice: Refer to Fastener Notice in Service Precautions. Tighten the pinion nut while holding the J 8614-01. ^ Tighten the pinion nut to 370 Nm (273 ft. lbs.). 9. Install the propeller shaft to the rear axle pinion yoke. 10. Inspect and add axle lubricant to the axle housing, if necessary. 11. Lower the vehicle. Drive Pinion Housing and/or Seal Replacement Drive Pinion Housing and/or Seal Replacement ^ Tools Required J 44414 Pinion Seal Installer - J 22912-01 Bearing Puller - J 24433 Pinion Cone and Side Bearing Installer - J 37624 Pinion Bearing Installer - J 8092 Driver Handle Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7370 - J 8608 Rear Pinion Bearing Race Installer - J 8614-01 Flange/Pulley Holding Tool Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 2. Drain the axle lubricant. 3. Remove the axle shafts. 4. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 5. Disconnect the propeller shaft from the axle. Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Support the propeller shaft as necessary. 6. Measure the amount of torque required to rotate the pinion and the ring gear. Use an inch-pound torque wrench. Record this measurement for reassembly. This will give the combined preload for the following components: ^ The pinion bearings ^ The pinion pilot bearing ^ The pinion oil seal ^ The differential case bearings 7. Place an alignment mark between the pinion and the pinion yoke. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7371 8. Remove the pinion gear bearing retainer bolts. 9. Remove the pinion gear bearing retainer and the pinion. 10. Remove the selective shim. 11. Measure the amount of torque required to rotate the pinion. Use an inch-pound torque wrench. Record this measurement for reassembly. 12. Install the J 8614-01 as shown. 13. Remove the pinion nut while holding the J 8614-01. 14. Remove the washer. 15. Install the J 8614-2 (2) and the J 8614-3 (1) into the J 8614-01 (3) as shown. 16. Remove the pinion yoke by turning the J 8614-3 (1) clockwise while holding the J 8614-01 (3). 17. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing. 18. Remove the outer pinion bearing. 19. Remove the pinion. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7372 20. Remove the collapsible spacer. 21. Remove the inner pinion bearing from the pinion using the J 22912-01 and a hydraulic press. 22. Remove the outer pinion bearing cup using a hammer and a brass drift in the slots provided.Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 23. Remove the inner pinion bearing cup using a hammer and a brass drift in the slots provided.Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7373 1. Install the inner pinion bearing cup into the pinion gear bearing retainer using the J 37624 (2) and the J 8092 (1). 2. Install the outer pinion bearing cup into the pinion gear bearing retainer using the J 8608 (2) and the J 8092 (1). 3. Install the inner pinion bearing using the J 24433.Press the bearing on until the cone seats on the pinion. 4. Install a new collapsible spacer. 5. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. 6. Install the pinion into the pinion gear bearing retainer. 7. Install the outer pinion bearing onto the pinion. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7374 8. Install a new pinion oil seal using the J 44414. 9. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke. 10. Install the pinion yoke. Align the marks made during removal. 11. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. Notice: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft. 12. Install the washer and a new pinion nut. 13. Install the J 8614-01 onto the pinion yoke as shown. 14. Tighten the pinion nut while holding the J 8614-01. ^ Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Notice: Refer to Fastener Notice in Service Precautions. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 15. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal. ^ Tighten the nut in small increments, as needed, until the rotating torque is 0.40-0.57 Nm (3-5 inch lbs.) greater than the rotating torque recorded during removal. 16. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 7375 17. Determine the selective shim thickness for the pinion gear bearing retainer. 18. Apply sealant, GM P/N 1052942 (Canadian P/N 10953466) or equivalent, to sealing surface of the pinion gear bearing retainer. 19. Install the selective shim.Align the tab on the shim with the unmachined surface of the pinion gear bearing retainer. 20. Apply sealant, GM P/N 1052942 (Canadian P/N 10953466) or equivalent, to surface of the selective shim. 21. Install the pinion gear bearing retainer. 22. Install the pinion gear bearing retainer bolts. ^ Tighten the pinion gear bearing retainer bolts to 88 Nm (65 ft. lbs.). 23. Measure the rotating torque of the pinion and the ring gear. Compare this measurement with the rotating torque recorded during removal. The rotating torque of the pinion and the ring gear should be between 3.9-6.2 Nm (30-55 inch lbs.) for new bearings or 2.8-5.6 Nm (25-50 inch lbs.) for used bearings. 24. If the rotating torque of the pinion and the ring gear is not within specifications, adjust the preload of the pinion or the differential side bearings as necessary. 25. Install the propeller shaft (3) to the pinion yoke (4).Align the reference marks made during removal. 26. Install the propeller shaft yoke retaining clamps and the bolts. ^ Tighten the propeller shaft yoke retaining clamp bolts to 25 Nm (18 ft. lbs.). 27. Install the axle shafts. 28. Fill the axle with axle lubricant. 29. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Adjustments Axle Bearing: Adjustments WHEEL BEARING ADJ. (With Full Floating 10.5" or 11.5" Ring Gear) IMPORTANT: Ensure the brakes are fully released and do not drag. ^ Pull or push the tire at the top back and forth in order to test the wheel bearing play. ^ Use a pry bar under the tire as an alternative. ^ If the wheel bearing adjustment is correct, the movement will be barely noticeable. ^ If the movement is excessive, adjust the bearings. Adjustment Procedure Tools Required J 2222-C Wheel Bearing Nut Wrench 1. Raise the vehicle. 2. Remove the axle shaft. 3. Remove the hub adjuster nut retaining ring. 4. Remove the adjuster nut lock key. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Adjustments > Page 7380 5. Tighten the wheel bearing adjusting nut using the J 2222-C. ^ Rotate the hub in the opposite direction to the way the adjuster nut is turning. ^ Ensure the inner bearing and the seal seats against the spindle shoulder. TIGHTEN ^ Adjusting nut to 70 Nm (52.0 lb ft). 6. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 7. Turn the adjusting nut clockwise until the nut contacts the bearing cone. Torque on the nut must be zero to finger tight. 8. Insert the adjusting nut lock key into the keyway using one of the following procedures: ^ If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. IMPORTANT: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. ^ If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Adjustments > Page 7381 9. Install the retaining ring. 10. Install the axle shaft. 11. Inspect the lubricant level and add, if necessary. 12. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > With Full Floating 10.5 Axle Bearing: Service and Repair With Full Floating 10.5" or 11.5" Ring Gear Rear Axle Hub, Bearing, Cup, and/or Seal Replacement ^ Tools Required J 8092 Universal Driver Handle - 3/4 inch - 10 - J 2222-C Wheel Bearing Nut Wrench - J 24426 Wheel Bearing Race Installer - Outer - J 24427 Wheel Bearing Race Installer - Inner - J 44419 Hub Outer Bearing Race Installer - J 44420 Differential Bearing and Hub Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper. 4. Remove the axle shaft. 5. Remove the axle nut retaining ring. 6. Remove the key. 7. Remove the adjusting nut using the J 2222-C. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > With Full Floating 10.5 8. Remove the adjusting nut. 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary. 11. Remove the oil seal from the wheel hub using a suitable seal removal tool. 12. Remove the inner hub bearing. 13. Remove the inner hub bearing cup using a brass drift and a hammer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > With Full Floating 10.5 14. Remove the retaining ring from the wheel hub. 15. Remove the outer hub bearing and bearing cup using the J 24426 (2) and the J 8092 (1). Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: ^ The outer wheel bearing ^ The inner wheel bearing ^ The outer wheel bearing cup ^ The inner wheel bearing cup ^ The axle housing 2. Install the outer bearing into the wheel hub. 3. Install the outer bearing cup into the wheel hub. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > With Full Floating 10.5 4. Drive the bearing cup into the wheel hub using the J 44419 (2) and the J 8092 (1). 5. Install the retaining ring into the groove. Make sure the retaining ring is fully and evenly seated in the groove. 6. Install the inner bearing cup. 7. Drive the inner bearing cup into the wheel hub using the J 24427 (2) and the J 8092 (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > With Full Floating 10.5 8. Install the inner bearing. 9. Important: Each time you replace the wheel hub bearings, install a new oil seal in order to prevent the wheel hub from leaking. Install the new oil seal using the J 44420 (2) and the J 8092 (1). 10. Install the rotor, if necessary. 11. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. 12. Install the wheel hub to the axle housing. 13. Install the adjusting nut to the hub using the J 2222-C. 14. Adjust the wheel bearings. 15. Install the axle shaft. 16. Install the brake caliper. 17. Install the tire and wheel assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > With Full Floating 10.5 18. Inspect and add axle lubricant to the axle housing, if necessary. 19. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > With Full Floating 10.5 Axle Bearing: Service and Repair With Semi Floating 8.6", 9.5", 9.75" Ring Gear Rear Axle Shaft Seal and/or Bearing Replacement ^ Tools Required J 8092 Universal Driver Handle-3/4 in - 10 - J 21128 Axle Pinion Oil Seal Installer (8.6 inch Axle) - J 23690 Axle Shaft Bearing Installer (8.6 inch Axle) - J 2619-01 Slide Hammer - J 29709 Wheel Bearing Installer (9.5 inch Axle) - J 29712 Wheel Bearing Remover (9.5 inch Axle) - J 29713 Axle Seal Installer (9.5 inch Axle) - J 44685 Rear Axle Seal and Bearing Remover (8.6 inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the rear axle housing cover. 4. Remove the axle shaft. 5. Remove the axle shaft seal and the bearing from the axle housing using the J 44685 (8.6 inch axle) (1) and the J 2619-01 (2). 6. Remove the axle shaft seal and the bearing from the axle housing using the J 29712 (9.5 inch axle). Installation Procedure 1. Install the axle shaft bearing using the J 23690 (8.6 inch axle) (1) or the J 29709 (9.5 inch axle) (1) and the J 8092 (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > With Full Floating 10.5 2. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. 3. Install the axle shaft seal using the J 21128 (8.6 inch axle) or the J 29713 (9.5 inch axle). 4. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 5. Install the axle shaft. 6. Install the rear axle housing cover. 7. Install the tire and wheel assembly. 8. Fill the rear axle. 9. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Rear Axle Shaft Replacement Axle Shaft: Service and Repair Rear Axle Shaft Replacement 8.6 Inch, 9.5 Inch Axles Rear Axle Shaft Replacement (8.6 Inch, 9.5 Inch Axles) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper. 4. Remove the rear cover and the gasket. 5. Remove the pinion shaft locking bolt. 6. On axles without a locking differential, remove the pinion shaft. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Rear Axle Shaft Replacement > Page 7396 7. On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing. 8. On axles with a locking differential, use a screwdriver, or a similar tool, in order to enter the differential case and rotate the lock (1) until the lock aligns with the thrust block (2). 9. Push the flange of the axle shaft (1) toward the differential. 10. Remove the C-lock (4) from the button end of the axle shaft (1). 11. Important: When removing the axle shaft, do not rotate the shaft. Rotating the shaft will misalign the gears. Misaligning the gears will make the assembly difficult. Remove the axle shaft (1) from the housing (5). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Rear Axle Shaft Replacement > Page 7397 Installation Procedure 1. Important: Carefully insert the axle shaft in order to not damage the seal. Install the axle shaft (1) into the rear axle housing (5). 2. Slide the axle shaft (1) into place allowing the splines to engage the differential side gear. 3. On axles without a locking differential, place the lock (4) on the button end of the axle shaft (1). 4. On axles with a locking differential, keep the pinion shaft partially withdrawn. 5. On axles with a locking differential, place the C-lock (1) on the axle shaft (3) so that the ends are flush with the thrust block (2). 6. Pull the shaft flange outward in order to seat the lock in the differential gear. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Rear Axle Shaft Replacement > Page 7398 7. Align the hole in the pinion shaft with the bolt hole in the differential case. 8. Notice: Refer to Fastener Notice in Service Precautions. Install the new pinion shaft locking bolt. ^ For the 8.6 inch axle, tighten the pinion shaft locking bolt to 36 Nm (27 ft. lbs.). ^ For the 9.5 inch axle, tighten the pinion shaft locking bolt to 50 Nm (37 ft. lbs.). 9. Install the rear cover and the gasket. 10. Install the brake caliper. 11. Install the tire and wheel assembly. 12. Fill the rear axle. Use the proper fluid. 13. Lower the vehicle. 9.75 Inch Axle Rear Axle Shaft Replacement (9.75 Inch Axle) Removal Procedure 1. Release the park brake. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the tire and wheel assembly. 4. Remove the rear steering gear assembly. 5. Remove the steering knuckle assembly. 6. Remove the lock clip from the axle shaft end. The lock clip is spring loaded and fits securely in the axle shaft slot and may need to be push off the shaft end with a screw driver or related tool. Pushing the axle shaft inwards towards the gears my help in removal of the lock clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Rear Axle Shaft Replacement > Page 7399 7. Important: When removing the axle shaft do not rotate the shaft. Rotating the shaft will cause the gears to move. Misalignment of the gears will make the assembly difficult. Remove the axle shaft. Installation Procedure 1. Install the axle shaft. 2. Install the spring loaded lock clip to the axle shaft end. 3. Install the steering knuckle assembly. 4. Install the rear steering gear assembly. 5. Install the tire and wheel assembly. 6. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Rear Axle Shaft Replacement > Page 7400 Axle Shaft: Service and Repair Rear Axle Shaft and/or Gasket Replacement Rear Axle Shaft and/or Gasket Replacement Removal Procedure 1. Remove the flange bolts. 2. Lightly tap the axle shaft with a soft-faced hammer in order to loosen the shaft. 3. Grip the rib on the axle shaft flange with a locking pliers. Twist the axle shaft flange in order to start the axle shaft removal. 4. Remove the axle shaft from the tube. 5. Remove the gasket. 6. Clean the axle shaft flange and the outside face of the hub assembly. Installation Procedure 1. Install the gasket onto the axle shaft. 2. Install the gasket and the axle shaft into the axle tube. 1. Ensure the shaft splines mesh into the differential side gear. 2. Align the holes in the axle flange and the gasket with the holes in the hub. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the axle flange bolts. ^ For the 10.5 inch axle, tighten the rear axle flange bolts to 156 Nm (115 ft. lbs.). ^ For the 11.5 inch axle, tighten the rear axle flange bolts to 200 Nm (148 ft. lbs.). 4. Inspect and add axle lubricant to the axle housing, if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement Constant Velocity Joint: Service and Repair Inner Joint and Seal Replacement Wheel Drive Shaft Inner Joint and Seal Replacement ^ Tools Required J 35910 Seal Clamp Tool - J 36652 Drive Axle Clamp Swage Tool - J 36652-98 Axle Swage Tool Disassembly Procedure 1. Use a hand grinder in order to cut through the swage ring (2). Important: Use caution when using the hand grinder by the tripot housing (1). 2. Remove the tripot housing (1) from the halfshaft. 3. Wipe the grease off of the housing (1). 4. Thoroughly degrease the tripot housing (1). 5. Allow the tripot housing (1) to dry prior to assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7405 6. Using side cutters, remove the small boot retaining clamp. 7. Remove the following items from the halfshaft bar: 1. The spacer ring (1) 2. The tripot spider assembly (2) 3. The tripot boot (3) 8. Clean the halfshaft bar (4). Use a wire brush in order to remove any rust in the seal mounting area (grooves). 9. Inspect the needle rollers, needle bearings, and trunnion. Inspect the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts with the appropriate service kit. Assembly Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7406 1. Place the new small seal clamp (2) onto the small end of the joint seal (1). Compress the joint seal (1) and small seal clamp (2) onto the halfshaft bar. 2. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar. 3. Secure the small seal clamp (1) with J 35910 , or equivalent, a breaker bar, and a torque wrench. ^ Tighten the small seal clamp (1) to 136 Nm (100 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Inspect the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7407 5. Install the convolute retainer tool over the inboard joint seal, being sure to capture the following convolutions: ^ 2-5 for the 1500 model (except 1500 HD) ^ 2-4 for the 1500 HD, 2500, 3500, and Hummer H2 models. Important: Assemble the tripot joint with the convolute retainer in the correct position, as illustrated. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7408 6. Install the tripot spider assembly (3) onto the halfshaft bar (2). 7. Install the spacer ring (1) in the groove at the end of the halfshaft bar (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7409 8. Pack the tripot seal (4) and the tripot housing (1) with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7410 9. Assemble the tripot housing and the tripot seal using the following procedure: 1. Pinch the swage ring (2) slightly by hand in order to distort it into an oval shape. 2. Slide the distorted swage ring (2) over the large diameter of the seal. 3. Place the tripot housing over the spider assembly. 4. Install the seal onto the tripot housing. 5. Align the tripot seal (1), with the swage ring (2) in place, over the flat area on the tripot housing (3). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7411 10. For the 1500 models (except 1500 HD), assemble the bolts and the support plate to the base of the J-36652-01 and secure the base in a vise. 11. For the 1500 HD, 2500, 3500, and HUMMER H2 models, assemble the bolts and the support plate to the base of the J 36652-98 and secure the base in a vise. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7412 12. Position the inboard end (tripot end) of the halfshaft assembly into the base of the J-36652-01 for the 1500 models (except 1500 HD) or J 36652-98 for the 1500 HD, 2500, 3500 and Hummer H2 models. 13. Install the top half of the J-36652-01 for the 1500 models (except 1500 HD) or J 36652-98 for the 1500 HD, 2500, 3500 and HUMMER H2 models. 14. Align the swage ring (2) and the swage ring clamp. 15. Insert the bolts. Hand tighten the bolts until the bolts are snug. 16. Align the following during this procedure: ^ The tripot boot (3) ^ The tripot housing (1) ^ The swage ring (2) ^ Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of the tool touch the bottom half . ^ Loosen the bolts and remove the halfshaft assembly from the tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7413 17. Inspect the inboard stroke position. ^ Use measurement A for the 1500 models (except 1500 HD). ^ Use measurement B for the 1500 HD, 2500, 3500, and Hummer H2 models. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7414 18. Remove the convolute retainer tool from the boot. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7415 Constant Velocity Joint: Service and Repair Outer Joint and Seal Replacement Wheel Drive Shaft Outer Joint and Seal Replacement ^ Tools Required J 8059 Snap Ring Pliers - J 35910 Seal Clamp Tool - J 36652 Drive Axle Clamp Swage Tool Disassembly Procedure 1. Use a hand grinder to cut through the swage ring (2). Important: Use caution when using the hand grinder by the CV joint outer race (1). 2. Use side cutters to cut off the small boot clamp (4). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7416 3. Slide the boot (5) down the halfshaft bar (4) and away from the CV joint outer race (1). 4. Wipe all grease away from the face of the CV joint. 5. Find the halfshaft bar retaining snap ring (3), which is located in the inner race (2). 6. Spread the snap ring ears apart using J 8059 (or equivalent). 7. Pull the CV joint (1) and the CV joint boot (5) from the halfshaft bar (4). 8. Discard the old CV joint boot (5). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7417 9. Place a brass drift against the CV joint cage (1). 10. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 11. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts. 12. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2). 13. Repeat this process to remove all six of the balls. 14. Pivot the CV joint cage (4) and the inner race 90 degrees to the center line of the outer race (1). At the same time, align the cage windows (3) with the lands of the outer race (2). 15. Lift out the cage (4) and the inner race. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7418 16. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 17. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. 1. The inner and outer race assemblies 2. The CV joint cage 3. The chrome alloy balls 18. Dry all the parts. 19. Check the CV joint assembly for unusual wear, cracks, or other damage. 20. Replace any damaged parts. 21. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves). Assembly Procedure 1. Inspect all of the parts for unusual wear, cracks, or other damage. Replace the CV joint assembly if necessary. 2. Put a light coat of the recommended grease on the inner (6) and the outer race (8) grooves. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7419 3. Hold the inner race (1) at 90 degrees to the centerline of the cage (2). 4. Align the lands of the inner race (1) with the windows of the cage (2). 5. Insert the inner race (1) into the cage (2), by rotating the inner race (1) downward. 6. Insert the cage (4) and inner race into the outer race (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7420 7. Place a brass drift against the CV joint cage (1). 8. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 9. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts. 10. Tilt the CV joint cage (1) in the opposite direction to install the opposing chrome alloy ball (2). 11. Repeat this process in order to install all six of the balls. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7421 12. Pack the CV joint boot (1) and the CV joint assembly with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. 13. Place the new small boot clamp (2) onto the CV joint seal (1). 14. Slide the CV joint boot (1) onto the halfshaft bar. 15. Position the small end of the CV joint boot (1) into the joint boot groove (3) on the halfshaft bar. 16. Secure the small boot clamp (1) using J 35910 (or equivalent), a breaker bar, and a torque wrench. ^ Tighten the small clamp (1) to 136 Nm (100 ft. lbs.). 17. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7422 18. Pinch the new swage ring (2) slightly by hand to distort it into an oval shape. 19. Slide the distorted swage ring (2) over the large diameter of the boot (1). 20. Slide the CV joint (4) onto the halfshaft bar (3). The retaining snap ring inside of the inner race engages in the halfshaft bar groove with a click when the CV joint (4) is in the proper position. Pull on the CV joint (4) to verify engagement. Important: Be sure that the retaining ring side of the CV joint inner race faces the halfshaft bar (3) before installation. 21. Slide the large diameter of the CV joint boot (1), with the large swage ring (2) in place, over the outside edge of the CV joint outer race (4). 22. Clamp the CV joint boot (2) tightly to the CV joint outer race (1) with the large swage ring (4), using the following procedure: 23. Mount the base of J 36652 in a vise. 24. Position the CV joint end (outboard end) of the halfshaft assembly in the bottom half of J 36652. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7423 25. Align the following during this procedure: ^ The CV joint boot (3) ^ The CV joint assembly (1) ^ The swage ring (2) 26. Install the top half of J 36652 onto the lower half of the tool, over the CV joint boot (3) and the CV joint assembly (1). 27. Align the swage ring (2) and the swage ring clamp. 28. Insert the bolts into J 36652. Hand tighten the bolts until the bolts are snug. ^ Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of J 36652 touch the bottom half of the tool. 29. Loosen the bolts and remove the halfshaft assembly from J 36652. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement Constant Velocity Joint Boot: Service and Repair Inner Joint and Seal Replacement Wheel Drive Shaft Inner Joint and Seal Replacement ^ Tools Required J 35910 Seal Clamp Tool - J 36652 Drive Axle Clamp Swage Tool - J 36652-98 Axle Swage Tool Disassembly Procedure 1. Use a hand grinder in order to cut through the swage ring (2). Important: Use caution when using the hand grinder by the tripot housing (1). 2. Remove the tripot housing (1) from the halfshaft. 3. Wipe the grease off of the housing (1). 4. Thoroughly degrease the tripot housing (1). 5. Allow the tripot housing (1) to dry prior to assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7428 6. Using side cutters, remove the small boot retaining clamp. 7. Remove the following items from the halfshaft bar: 1. The spacer ring (1) 2. The tripot spider assembly (2) 3. The tripot boot (3) 8. Clean the halfshaft bar (4). Use a wire brush in order to remove any rust in the seal mounting area (grooves). 9. Inspect the needle rollers, needle bearings, and trunnion. Inspect the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts with the appropriate service kit. Assembly Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7429 1. Place the new small seal clamp (2) onto the small end of the joint seal (1). Compress the joint seal (1) and small seal clamp (2) onto the halfshaft bar. 2. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar. 3. Secure the small seal clamp (1) with J 35910 , or equivalent, a breaker bar, and a torque wrench. ^ Tighten the small seal clamp (1) to 136 Nm (100 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Inspect the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7430 5. Install the convolute retainer tool over the inboard joint seal, being sure to capture the following convolutions: ^ 2-5 for the 1500 model (except 1500 HD) ^ 2-4 for the 1500 HD, 2500, 3500, and Hummer H2 models. Important: Assemble the tripot joint with the convolute retainer in the correct position, as illustrated. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7431 6. Install the tripot spider assembly (3) onto the halfshaft bar (2). 7. Install the spacer ring (1) in the groove at the end of the halfshaft bar (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7432 8. Pack the tripot seal (4) and the tripot housing (1) with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7433 9. Assemble the tripot housing and the tripot seal using the following procedure: 1. Pinch the swage ring (2) slightly by hand in order to distort it into an oval shape. 2. Slide the distorted swage ring (2) over the large diameter of the seal. 3. Place the tripot housing over the spider assembly. 4. Install the seal onto the tripot housing. 5. Align the tripot seal (1), with the swage ring (2) in place, over the flat area on the tripot housing (3). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7434 10. For the 1500 models (except 1500 HD), assemble the bolts and the support plate to the base of the J-36652-01 and secure the base in a vise. 11. For the 1500 HD, 2500, 3500, and HUMMER H2 models, assemble the bolts and the support plate to the base of the J 36652-98 and secure the base in a vise. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7435 12. Position the inboard end (tripot end) of the halfshaft assembly into the base of the J-36652-01 for the 1500 models (except 1500 HD) or J 36652-98 for the 1500 HD, 2500, 3500 and Hummer H2 models. 13. Install the top half of the J-36652-01 for the 1500 models (except 1500 HD) or J 36652-98 for the 1500 HD, 2500, 3500 and HUMMER H2 models. 14. Align the swage ring (2) and the swage ring clamp. 15. Insert the bolts. Hand tighten the bolts until the bolts are snug. 16. Align the following during this procedure: ^ The tripot boot (3) ^ The tripot housing (1) ^ The swage ring (2) ^ Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of the tool touch the bottom half . ^ Loosen the bolts and remove the halfshaft assembly from the tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7436 17. Inspect the inboard stroke position. ^ Use measurement A for the 1500 models (except 1500 HD). ^ Use measurement B for the 1500 HD, 2500, 3500, and Hummer H2 models. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7437 18. Remove the convolute retainer tool from the boot. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7438 Constant Velocity Joint Boot: Service and Repair Outer Joint and Seal Replacement Wheel Drive Shaft Outer Joint and Boot Replacement - J 8059 Snap Ring Pliers - J 35910 Drive Axle Seal Clamp Pliers - J 36652-1 Drive Axle Clamp Swage Tool - J 36652-2 Axle Swage Tool Removal Procedure 1. Remove the wheel drive shaft. 2. Remove the wheel drive shaft seal cover, if applicable. Important: Use caution when using the hand grinder by the CV joint outer race (1). 3. Use a hand grinder to cut through the swage ring (2). 4. Use side cutters to cut off the small boot clamp (4). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7439 5. Slide the boot (5) down the halfshaft bar (4) and away from the CV joint outer race (1). 6. Wipe all grease away from the face of the CV joint. 7. Find the halfshaft bar retaining snap ring (3), which is located in the inner race (2). 8. Spread the snap ring ears apart using J 8059 (or equivalent). 9. Pull the CV joint (1) and the CV joint boot (5) from the halfshaft bar (4). 10. Discard the oil CV joint boot (5). 11. Place a brass drift against the CV joint cage (1). 12. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 13. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts. 14. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2). 15. Repeat this process to remove all six of the balls. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7440 16. Pivot the CV joint cage (4) and the inner race 90 degrees to the center line of the outer race (1). At the same time, align the cage windows (3) with the lands of the outer race (2). 17. Lift out the cage (4) and the inner race. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7441 18. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 19. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. 19.1. The inner and outer race assemblies 19.2. The CV joint cage 19.3. The chrome alloy balls. 20. Dry all the parts. 21. Check the CV joint assembly for unusual wear, cracks, or other damage. 22. Replace any damaged parts. 23. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves). Installation Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7442 1. Inspect all of the parts for unusual wear, cracks, or other damage. Replace the CV joint assembly if necessary. 2. Put a light coat of the recommended grease on the inner (6) and the outer race (8) grooves. 3. Hold the inner race (1) at 90 degrees to the centerline of the cages (2). 4. Align the lands of the inner race (1) with the windows of the cage (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7443 5. Insert the inner race (1) into the cage (2), by rotating the inner race (1) downward. 6. Insert the cage (4) and inner race into the outer race (1). 7. Place a brass drift against the CV joint cage (1). 8. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 9. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts. 10. Tilt the CV joint cage (1) in the opposite direction to install the opposing chrome alloy ball (2). 11. Repeat this process in order to install all six of the balls. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7444 12. Pack the CV joint boot (1) and the CV joint assembly with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. 13. Place the new small boot clamp (2) onto the CV joint seal (1). 14. Slide the CV joint boot (1) onto the halfshaft bar. 15. Position the small end of the CV joint boot (1) into the joint boot groove (3) on the halfshaft bar. Notice: Refer to Fastener Notice in the Preface. 16. Secure the small boot clamp (1) using J35910 (or equivalent), a breaker bar, and a torque wrench. Tighten the small clamp (1) to 136 Nm (100 lb ft). 17. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reacted. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7445 18. Pinch the new swage ring (2) slightly by hand to distort it into an oval shape. 19. Slide the distorted swage ring (2) over the large diameter of the boot (1). Important: Be sure that the retaining ring side of the CV joint inner race faces the halfshaft bar (3) before installation. 20. Slide the CV joint (4) onto the halfshaft bar (3) The retaining snap ring inside of the inner race engages in the halfshaft bar groove with a clock when the CV joint (4) is in the proper position. 21. Pull on the CV joint (4) to verify engagement. 22. Slide the large diameter of the CV joint boot (1), with the large swage ring (2) in place, over the outside edge of the CV joint outer race (4). 23. Clamp the CV joint boot (2) tightly to the CV joint outer race (1) with the large swage ring (4), using the following procedure: 24. For the 1500 models, assemble the bolts and the support plate to the base of the J 36652-1 and secure the base in a vise. For the 2500 and 3500 models, use the J36652-2. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Joint and Seal Replacement > Page 7446 25. Position the CV joint end (outboard end) of the halfshaft assembly in the bottom half of the J 36652-1 or J 36652-2. 26. Align the following during this procedure: - The CV joint boot (3) - The CV joint assembly (1) - The swage ring (2) 27. Install the top half of J 36652-1 or J 36652-2 onto the lower half of the tool, over the the CV joint boot (3) and the CV joint assembly (1). 28. Align the swage ring (2) and the swage ring clamp. 29. Insert the bolts onto J 36652-1 or J 36652-2. Hand tighten the bolts until the bolts are snug. Tighten each bolt 180 degrees at a time. Alternate between the bolts until both side of the top half of the tool touch the bottom half of the tool. 30. Loosen the bolts and remove the halfshaft assembly from the tool. 31. Install the wheel drive shaft seal cover, if applicable. 32. Install the wheel drive shaft. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 7460 Seals and Gaskets: By Symptom Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 7461 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 7462 Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer Seals and Gaskets: Service and Repair Rear Axle Shaft Seal Replacement - Outer Rear Axle Shaft Seal Replacement - Outer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the axle shaft. 4. Remove the axle shaft seal. Installation Procedure 1. Install the axle shaft seal. 2. Install the axle shaft. 3. Install the tire and wheel assembly. 4. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 7465 Seals and Gaskets: Service and Repair Rear Axle Shaft Seal Replacement - Inner Rear Axle Shaft Seal Replacement - Inner ^ Tools Required J 33049 Camshaft Bearing Service Set - J 45177 Differential Seal Installer - Inner Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the axle shafts. 4. Remove the differential assembly. 5. Install the smallest expanding driver (3) and the small driving washer (1) onto the expander assembly (2). 6. Align the separation lines between the expanding driver and the expander assembly. 7. Assemble the expander assembly (2) onto the driver bar extension (1). 8. Assemble the drive bar extension onto the driver bar. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 7466 9. Insert the J 33049 into the axle tube and through the axle shaft seal. 10. While holding the expander assembly nut, turn the driving bar clockwise until the expanding driver is snug against the axle shaft seal. 11. Drive out the seal using the J 33049 and a hammer. Installation Procedure 1. Assemble the drive bar extension onto the drive bar of J 33049. 2. Insert the J 33049 into the opposite side axle shaft tube. 3. Install the J 45177 onto the J 33049. 4. Insert the axle shaft seal into the axle tube. 5. Install the J 45177 (1) and the J 33049 (2) over the axle shaft seal. 6. Drive the axle shaft seal into the axle tube using the J 45177 , the J 33049 and a hammer. 7. Install the differential assembly. 8. Install the axle shafts. 9. Install the tire and wheel assembly. 10. Lower the vehicle. Refer to Vehicle Lifting. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 7467 Seals and Gaskets: Service and Repair Rear Axle Shaft Seal and/or Bearing Replacement Rear Axle Shaft Seal and/or Bearing Replacement ^ Tools Required J 8092 Universal Driver Handle-3/4 in - 10 - J 21128 Axle Pinion Oil Seal Installer (8.6 inch Axle) - J 23690 Axle Shaft Bearing Installer (8.6 inch Axle) - J 2619-01 Slide Hammer - J 29709 Wheel Bearing Installer (9.5 inch Axle) - J 29712 Wheel Bearing Remover (9.5 inch Axle) - J 29713 Axle Seal Installer (9.5 inch Axle) - J 44685 Rear Axle Seal and Bearing Remover (8.6 inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the rear axle housing cover. 4. Remove the axle shaft. 5. Remove the axle shaft seal and the bearing from the axle housing using the J 44685 (8.6 inch axle) (1) and the J 2619-01 (2). 6. Remove the axle shaft seal and the bearing from the axle housing using the J 29712 (9.5 inch axle). Installation Procedure 1. Install the axle shaft bearing using the J 23690 (8.6 inch axle) (1) or the J 29709 (9.5 inch axle) (1) and the J 8092 (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 7468 2. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. 3. Install the axle shaft seal using the J 21128 (8.6 inch axle) or the J 29713 (9.5 inch axle). 4. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 5. Install the axle shaft. 6. Install the rear axle housing cover. 7. Install the tire and wheel assembly. 8. Fill the rear axle. 9. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 7469 Seals and Gaskets: Service and Repair Rear Axle Shaft and/or Gasket Replacement Rear Axle Shaft and/or Gasket Replacement Removal Procedure 1. Remove the flange bolts. 2. Lightly tap the axle shaft with a soft-faced hammer in order to loosen the shaft. 3. Grip the rib on the axle shaft flange with a locking pliers. Twist the axle shaft flange in order to start the axle shaft removal. 4. Remove the axle shaft from the tube. 5. Remove the gasket. 6. Clean the axle shaft flange and the outside face of the hub assembly. Installation Procedure 1. Install the gasket onto the axle shaft. 2. Install the gasket and the axle shaft into the axle tube. 1. Ensure the shaft splines mesh into the differential side gear. 2. Align the holes in the axle flange and the gasket with the holes in the hub. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the axle flange bolts. ^ For the 10.5 inch axle, tighten the rear axle flange bolts to 156 Nm (115 ft. lbs.). ^ For the 11.5 inch axle, tighten the rear axle flange bolts to 200 Nm (148 ft. lbs.). 4. Inspect and add axle lubricant to the axle housing, if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 7470 Seals and Gaskets: Service and Repair Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Rear Axle Hub, Bearing, Cup, and/or Seal Replacement ^ Tools Required J 8092 Universal Driver Handle - 3/4 inch - 10 - J 2222-C Wheel Bearing Nut Wrench - J 24426 Wheel Bearing Race Installer - Outer - J 24427 Wheel Bearing Race Installer - Inner - J 44419 Hub Outer Bearing Race Installer - J 44420 Differential Bearing and Hub Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper. 4. Remove the axle shaft. 5. Remove the axle nut retaining ring. 6. Remove the key. 7. Remove the adjusting nut using the J 2222-C. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 7471 8. Remove the adjusting nut. 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary. 11. Remove the oil seal from the wheel hub using a suitable seal removal tool. 12. Remove the inner hub bearing. 13. Remove the inner hub bearing cup using a brass drift and a hammer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 7472 14. Remove the retaining ring from the wheel hub. 15. Remove the outer hub bearing and bearing cup using the J 24426 (2) and the J 8092 (1). Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: ^ The outer wheel bearing ^ The inner wheel bearing ^ The outer wheel bearing cup ^ The inner wheel bearing cup ^ The axle housing 2. Install the outer bearing into the wheel hub. 3. Install the outer bearing cup into the wheel hub. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 7473 4. Drive the bearing cup into the wheel hub using the J 44419 (2) and the J 8092 (1). 5. Install the retaining ring into the groove. Make sure the retaining ring is fully and evenly seated in the groove. 6. Install the inner bearing cup. 7. Drive the inner bearing cup into the wheel hub using the J 24427 (2) and the J 8092 (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 7474 8. Install the inner bearing. 9. Important: Each time you replace the wheel hub bearings, install a new oil seal in order to prevent the wheel hub from leaking. Install the new oil seal using the J 44420 (2) and the J 8092 (1). 10. Install the rotor, if necessary. 11. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. 12. Install the wheel hub to the axle housing. 13. Install the adjusting nut to the hub using the J 2222-C. 14. Adjust the wheel bearings. 15. Install the axle shaft. 16. Install the brake caliper. 17. Install the tire and wheel assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Shaft Seal Replacement - Outer > Page 7475 18. Inspect and add axle lubricant to the axle housing, if necessary. 19. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Front Hub and Bearing Assembly to Steering Knuckle Bolts ............................................................................................................... 180 Nm (133 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 7479 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Test 1-7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 7480 Wheel Bearing: Adjustments Rear Wheel Bearing Adjustment (With Full Floating 10.5" or 11.5" Ring Gear) IMPORTANT: Ensure the brakes are fully released and do not drag. ^ Pull or push the tire at the top back and forth in order to test the wheel bearing play. ^ Use a pry bar under the tire as an alternative. ^ If the wheel bearing adjustment is correct, the movement will be barely noticeable. ^ If the movement is excessive, adjust the bearings. Adjustment Procedure Tools Required J 2222-C Wheel Bearing Nut Wrench 1. Raise the vehicle. 2. Remove the axle shaft. 3. Remove the hub adjuster nut retaining ring. 4. Remove the adjuster nut lock key. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 7481 5. Tighten the wheel bearing adjusting nut using the J 2222-C. ^ Rotate the hub in the opposite direction to the way the adjuster nut is turning. ^ Ensure the inner bearing and the seal seats against the spindle shoulder. TIGHTEN ^ Adjusting nut to 70 Nm (52.0 lb ft). 6. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 7. Turn the adjusting nut clockwise until the nut contacts the bearing cone. Torque on the nut must be zero to finger tight. 8. Insert the adjusting nut lock key into the keyway using one of the following procedures: ^ If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. IMPORTANT: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. ^ If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 7482 9. Install the retaining ring. 10. Install the axle shaft. 11. Inspect the lubricant level and add, if necessary. 12. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing Wheel Bearing: Service and Repair Front Wheel Bearing Front Wheel Hub, Bearing, and Seal Replacement (4WD) ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 5. Remove the wheel drive shaft nut retaining cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 7485 6. Important: Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 7486 8. Remove the wheel hub and the 15-series bearing mounting bolts (4). 9. Remove the wheel hub and bearing (4) mounting bolts, 25/35 series. 10. Remove the wheel hub and bearing and splash shield from the vehicle. 11. Remove the O-ring seal from the steering knuckle bore, 25/35 series. 12. Remove the wheel speed sensor mounting bolt (5). 13. Clean and inspect the O-ring seal, 25/35 series. 14. Replace the seal if the following conditions exist: ^ Nicks ^ Cuts ^ Dry or brittle ^ Compression set Installation Procedure 1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 3. Install the O-ring (7) to the steering knuckle, the 25/35 series. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. ^ Tighten the sensor mounting bolt to 18 Nm (13 ft. lbs.). 5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 7487 6. Install the wheel hub and bearing (5) and splash shield (6) to the vehicle, 15 series. 7. Install the wheel hub and bearing mounting bolts, the 15 series. 8. Install the wheel hub and bearing mounting bolts, 25/35 series. ^ Tighten the wheel hub to knuckle bolts to 180 Nm (133 ft. lbs.). 9. Install the nut (2) and washer (3) retaining the wheel drive shaft assembly to the wheel hub and bearing. ^ Tighten the nut to 240 Nm (177 ft. lbs.). 10. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. ^ Tighten the brake hose clip bolt to 12 Nm (106 inch lbs.). 11. Install the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 12. Install the tire and wheel. 13. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 7488 Wheel Bearing: Service and Repair With Full Floating 10.5" or 11.5" Ring Gear Rear Axle Hub, Bearing, Cup, and/or Seal Replacement ^ Tools Required J 8092 Universal Driver Handle - 3/4 inch - 10 - J 2222-C Wheel Bearing Nut Wrench - J 24426 Wheel Bearing Race Installer - Outer - J 24427 Wheel Bearing Race Installer - Inner - J 44419 Hub Outer Bearing Race Installer - J 44420 Differential Bearing and Hub Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper. 4. Remove the axle shaft. 5. Remove the axle nut retaining ring. 6. Remove the key. 7. Remove the adjusting nut using the J 2222-C. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 7489 8. Remove the adjusting nut. 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary. 11. Remove the oil seal from the wheel hub using a suitable seal removal tool. 12. Remove the inner hub bearing. 13. Remove the inner hub bearing cup using a brass drift and a hammer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 7490 14. Remove the retaining ring from the wheel hub. 15. Remove the outer hub bearing and bearing cup using the J 24426 (2) and the J 8092 (1). Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: ^ The outer wheel bearing ^ The inner wheel bearing ^ The outer wheel bearing cup ^ The inner wheel bearing cup ^ The axle housing 2. Install the outer bearing into the wheel hub. 3. Install the outer bearing cup into the wheel hub. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 7491 4. Drive the bearing cup into the wheel hub using the J 44419 (2) and the J 8092 (1). 5. Install the retaining ring into the groove. Make sure the retaining ring is fully and evenly seated in the groove. 6. Install the inner bearing cup. 7. Drive the inner bearing cup into the wheel hub using the J 24427 (2) and the J 8092 (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 7492 8. Install the inner bearing. 9. Important: Each time you replace the wheel hub bearings, install a new oil seal in order to prevent the wheel hub from leaking. Install the new oil seal using the J 44420 (2) and the J 8092 (1). 10. Install the rotor, if necessary. 11. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. 12. Install the wheel hub to the axle housing. 13. Install the adjusting nut to the hub using the J 2222-C. 14. Adjust the wheel bearings. 15. Install the axle shaft. 16. Install the brake caliper. 17. Install the tire and wheel assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 7493 18. Inspect and add axle lubricant to the axle housing, if necessary. 19. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 7494 Wheel Bearing: Service and Repair With Rear Wheel Steering Wheel Hub and Bearing Replacement ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. 4. Remove the axle nut dust cover (4). 5. Remove the cotter pin (2) and retainer (3) from the wheel drive shaft nut. 6. Remove the wheel drive shaft retaining nut. 7. Remove the wheel hub and bearing retaining bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 7495 8. Separate the wheel drive shaft from the wheel hub and bearing using J 45859 (2) or equivalent. 9. Remove the wheel hub and bearing (1) from the vehicle. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 7496 1. Install the wheel hub and bearing (3) to the vehicle. 2. Install the wheel hub and bearing retaining bolts. ^ Tighten the bolts to 180 Nm (132 ft. lbs.). 3. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel drive shaft retaining nut. ^ Tighten the nut to 250 Nm (184 ft. lbs.). 4. Install the retainer (3) and cotter pin (2) to the wheel drive shaft nut. 5. Install the dust cap (4). 6. Install the brake rotor. 7. Install the tire and wheel. 8. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Drivetrain - Wheel Drive Shaft Nut Torque Revision Axle Nut: Technical Service Bulletins Drivetrain - Wheel Drive Shaft Nut Torque Revision Bulletin No.: 04-04-95-001 Date: March 02, 2004 SERVICE MANUAL UPDATE Subject: Revised Wheel Drive Shaft Nut Torque Specification Models: 2002-2004 Cadillac Escalade, Escalade EXT 2003-2004 Cadillac Escalade ESV 1999-2004 Chevrolet Silverado 2000-2004 Chevrolet Suburban 2002-2004 Chevrolet Avalanche 2003-2004 Chevrolet Astro, Express 1999-2004 GMC Sierra 2000-2004 GMC Yukon, Yukon XL 2003-2004 GMC Safari, Savana 2003-2004 HUMMER H2 This bulletin is being issued to revise the torque specification for the wheel drive shaft nut in the Wheel Drive Shafts sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Drivetrain - Wheel Drive Shaft Nut Torque Revision > Page 7502 The torque specification for the wheel drive shaft nut has been revised as shown in the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Page 7503 Axle Nut: Specifications Axle Shaft Nut ...................................................................................................................................... ................................................ 240 Nm (177 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes Wheel Hub (Locking): Technical Service Bulletins Drivetrain - Gen II Vs. Gen III Wheel Hub Changes INFORMATION Bulletin No.: 08-03-08-003A Date: March 02, 2009 Subject: Wheel Hub Changes - Gen III vs. Gen II Models: 2008 and Prior Cadillac Escalade Models 2008 and Prior Chevrolet Avalanche, Silverado, Silverado Classic, Suburban, Tahoe 2008 and Prior GMC Sierra, Sierra Classic, Yukon Models Supercede: This bulletin is being revised to update the parts information in the table and to add an Illustrated Hub Gallery depicting all wheel hub part numbers called out below for visual identification purposes. Please discard Corporate Bulletin Number 08-03-08-003 (Section 03 - Suspension). General Motors Vehicle Engineering has introduced a new design Gen III front wheel hub for the above listed vehicles that replaces the Gen II product. These Gen II 4x2 and 4x4 applications that were previously serviced by seven part numbers are now serviced by three Gen III part numbers. Concerns have been expressed by technicians regarding the use of the new supersessions and whether the Gen III hubs will properly fit the vehicles being serviced, especially because of visual and functional differences (splines). This bulletin has been developed to address those concerns. Please refer to the table above for information on the Gen III replacement part for each Gen II application. At the end of the bulletin you will find an illustrated "Hub Gallery" with graphic depictions of both Gen II and replacement style Gen III parts. Using these illustrations you should be able to identify both the Gen II and Gen III wheel hubs. Warning If replacing wheel studs, please refer to the GM Parts Catalog for the correct stud part number for each application. Different types of studs are used depending on the wheel hub application. When replacing an older Gen II design 4x2 hub with a new 4x2/4x4 common Gen III hub, it is acceptable to have a bearing with splines on it for a 4x2 application that previously did not. However, the older Gen II design 4x4 hubs should NOT be used on a 4x2 vehicle. The Gen II 4x4 hub relies on the tension of the wheel drive shaft joint to hold everything together. The roll form feature on the inboard side of the new 4x2/4x4 Gen III hub eliminates this concern. The only hub that is not back serviceable is P/N 15719007 (not pictured) for 1999-2000 C25 applications due to a different hub flange to bearing flange offset. Important: Only the new part numbers referenced in this bulletin are interchangeable between the 4x2 and 4x4 applications with the exception of P/N 15719007 (Not Shown). Under no circumstances should any other 4x4 hub be used in a 4x2 application. Illustrated Hub Gallery Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 7508 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 7509 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 7510 The wheel hubs illustrated above are intended to provide enough visual details to identify subtle differences between the Gen II and Gen III replacement hubs. The various colors used in the graphics are not indicative of any difference or feature, but are used to increase the detail and clarity of the assembly. The associated part number is listed with each illustration. Please refer to the chart above for the specific application for each hub. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 7511 Please note the following when referring to a specific illustration: ^ When using the illustrations for back to back comparisons of two hubs, the most obvious differences are visible on the back side of the hubs. ^ The most common area of physical difference are in the shape of the four mounting bosses and their surrounds. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Seal > Component Information > Service and Repair Wheel Seal: Service and Repair Wheel Hub, Bearing, and Seal Replacement (4WD) ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 5. Remove the wheel drive shaft nut retaining cover. 6. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Seal > Component Information > Service and Repair > Page 7515 Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent. 8. Remove the wheel hub and the 15-series bearing mounting bolts (4). 9. Remove the wheel hub and bearing (4) mounting bolts, 25/35 series. 10. Remove the wheel hub and bearing and splash shield from the vehicle. 11. Remove the O-ring seal from the steering knuckle bore, 25/35 series. 12. Remove the wheel speed sensor mounting bolt (5). 13. Clean and inspect the O-ring seal, 25/35 series. 14. Replace the seal if the following conditions exist: ^ Nicks ^ Cuts Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Seal > Component Information > Service and Repair > Page 7516 ^ Dry or brittle ^ Compression set Installation Procedure 1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 3. Install the O-ring (7) to the steering knuckle, the 25/35 series. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. ^ Tighten the sensor mounting bolt to 18 Nm (13 ft. lbs.). 5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series. 6. Install the wheel hub and bearing (5) and splash shield (6) to the vehicle, 15 series. 7. Install the wheel hub and bearing mounting bolts, the 15 series. 8. Install the wheel hub and bearing mounting bolts, 25/35 series. ^ Tighten the wheel hub to knuckle bolts to 180 Nm (133 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Seal > Component Information > Service and Repair > Page 7517 9. Install the nut (2) and washer (3) retaining the wheel drive shaft assembly to the wheel hub and bearing. ^ Tighten the nut to 240 Nm (177 ft. lbs.). 10. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. ^ Tighten the brake hose clip bolt to 12 Nm (106 inch lbs.). 11. Install the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 12. Install the tire and wheel. 13. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair Center Support: Service and Repair Propeller Shaft Center Support Bearing Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the propeller shaft. 3. Remove the center bearing by doing the following: 1. Stand the propeller shaft (2) on end in the press (1) with the center bearing (3) supported by the press bars (4). 2. Press the propeller shaft (2) down and off the center bearing (3). Installation Procedure 1. Install the center bearing (3) onto the propeller shaft (2) by pressing the center bearing onto the shaft using a press (1). 2. Install the propeller shaft. 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Mechanical Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Mechanical Specifications > Page 7526 Sealers, Adhesives, and Lubricants Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Locations > Front Propeller Shaft Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Locations > Front Propeller Shaft > Page 7529 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Locations > Front Propeller Shaft > Page 7530 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Locations > Page 7531 Drive/Propeller Shaft: Description and Operation Propeller Shaft Description and Operation The propeller shaft is a tube with universal joints at both ends which do not require periodic maintenance, that transmit power from the transfer case or transmission output shaft to the differential. Front Propeller Shaft Description The front propeller shaft transmits rotating force from the transfer case to the front differential when the transfer case is engaged. The front propeller shaft connects to the transfer case using a splined slip joint. One Piece Propeller Shaft Description A 1 piece propeller shaft uses a splined slip joint to connect the driveline to the transmission or transfer case. Two Piece Propeller Shaft Description There are 3 universal joints used on the two piece propeller shaft, A center bearing assembly is used to support the propeller shaft connection point, and help isolate the vehicle from vibration. Propeller Shaft Phasing Description The propeller shaft is designed and built with the yoke lugs (ears) in line with each other. This produces the smoothest running shaft possible. A propeller shaft designed with built in yoke lugs in line is known as in - phase. An out of phase propeller shaft often causes vibration. The propeller shaft generates vibration from speeding up and slowing down each time the universal joint goes around. The vibration is the same as a person snapping a rope and watching the wave reaction flow to the end. An in phase propeller shaft is similar to 2 persons snapping a rope at the same time and watching the waves meet and cancel each other out. A total cancellation of vibration produces a smooth flow of power in the drive line. All splined shaft slip yokes are keyed in order to ensure proper phasing. Universal Joint Description The universal joint is connected to the propeller shaft. The universal consist of 4 caps with needle bearings and grease seals mounted on the trunnions of a cross or spider. These bearings and caps are greased at the factory and no periodic maintenance is required. There are 2 universal joints used in a one piece propeller shaft and 3 used in two piece propeller shaft. The bearings and caps are pressed into the yokes and held in place with snap rings, except for 2 bearings on some models witch are strapped onto the pinion flange of the differential. Universal joints are designed to handle the effects of various loads and rear axle windup conditions during acceleration and braking. The universal joint operates efficiently and safely within the designed angle variations. when the design angles are exceeded, the operational life of the joint decreases. Center Bearing Description Center bearings support the driveline when using 2 or more propeller shafts. The center bearing is a ball bearing mounted in a rubber cushion that attaches to a frame crossmember. The manufacturer prelubricates and seals the bearing. The cushion allows vertical motion at the driveline and helps isolate the vehicle from vibration. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive/Propeller Shaft: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Propeller Shaft Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Propeller Shaft in order to identify the correct procedure for diagnosing the system and where the procedure is located. See: Symptom Related Diagnostic Procedures/- Symptoms Propeller Shaft Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7534 Drive/Propeller Shaft: Symptom Related Diagnostic Procedures - Symptoms - Propeller Shaft Symptoms - Propeller Shaft Before beginning diagnosis, review the system description and operation in order to familiarize yourself with the system function. Refer to Propeller Shaft Description and Operation. Classifying the Symptom Propeller Shaft symptoms can usually be classified into the following categories: ^ Leaks ^ Noises ^ Vibrations Leak and noise related symptoms are diagnosed within the Propeller Shaft. For vibration related symptoms, refer to Diagnostic Starting Point - Vibration Diagnosis and Correction. Visual/Physical Inspection ^ Inspect the system for aftermarket devices which could affect the operation of the Propeller Shaft. ^ Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: ^ Leak at Front Slip Yoke See: Leak at Front Slip Yoke ^ Universal Joint Noise See: Universal Joint Noise ^ Ping, Snap, or Click Noise See: Ping, Snap, or Click Noise ^ Knock or Clunk Noise See: Knock or Clunk Noise ^ Scraping Noise See: Scraping Noise ^ Squeak Noise See: Squeak Noise Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7535 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7536 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement - One Piece Drive/Propeller Shaft: Service and Repair Propeller Shaft Replacement - One Piece Propeller Shaft Replacement - One Piece Removal Procedure 1. Important: Observe and accurately reference mark all driveline components relative to the propeller shaft and axles before disassembly. These components include the propeller shafts, the drive axles, the pinion flanges, the output shafts, etc. All components must be reassembled in the exact relationship to each other as they were when removed. In addition, published specifications and torque values, as well as any measurements made prior to disassembly must be followed. Raise the vehicle. Refer to Vehicle Lifting. 2. Reference mark the propeller shaft to the rear axle pinion yoke. 3. Reference mark the propeller shaft to the transmission or transfer case. 4. Remove the bolts (1) and the yoke retainers (2) from the rear axle pinion yoke (3). 5. Slide the propeller shaft forward in order to disconnect the propeller shaft from the rear axle pinion yoke. Notice: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 6. Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transmission or transfer case. 7. Remove the propeller shaft from the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement - One Piece > Page 7539 Installation Procedure 1. Inspect the splines of the slip yoke for a sufficient coating of grease. If the splines of the slip yoke does not have a sufficient coating of grease, lubricate the shaft with grease, GM P/N 12345879 or equivalent, RWD w/ Automatic Transmission Only. 2. Install the propeller shaft into the transmission or transfer case. Align the reference marks made during removal. 3. Install the propeller shaft (3) to the rear axle pinion yoke (4). Align the reference marks made during removal. 4. Install the yoke retainers (2) and bolts (1). ^ Tighten the yoke retainer bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement - One Piece > Page 7540 Drive/Propeller Shaft: Service and Repair Propeller Shaft Replacement - Two Piece Propeller Shaft Replacement - Two Piece ^ Tools Required J 43218 Clamp Pliers - Narrow Jaw Removal Procedure Important: Observe and accurately reference mark all driveline components relative to the propeller shaft and axles before disassembly. These components include the propeller shafts, the drive axles, the pinion flanges, the output shafts, etc. All components must be reassembled in the exact relationship to each other as they were when removed. In addition, published specifications and torque values, as well as any measurements made prior to disassembly must be followed. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 3. Reference mark the front propeller shaft to the transmission or transfer case (slip yoke type) or to the transmission pinion yoke (universal joint type). 4. Remove the clamp (2) securing the boot (3) to the front propeller shaft stub shaft (4) and the rear propeller shaft slip yoke (1) by prying up the exposed end of the clamp (2) using a flat bladed tool (if applicable). 5. Remove the bolts (1) and the yoke retainers (2) from the rear axle pinion yoke (4). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement - One Piece > Page 7541 6. Slide the rear propeller shaft forward in order to remove the propeller shaft from the rear axle pinion yoke. Notice: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 7. Slide the rear propeller shaft rearward in order to disconnect the rear propeller shaft from the front propeller shaft stub shaft. 8. Remove the rear propeller shaft from the vehicle. 9. Remove the boot from the front propeller shaft stub shaft (if applicable). 10. Remove the center bearing support nuts (1). 11. Remove the center bearing support (2). 12. Remove the front propeller shaft by sliding the front propeller shaft rearward from the transmission or the transfer case, w/o RPO MW3 or M74. 13. Remove the bolts and the yoke retainers from the transmission pinion yoke, w/ RPO MW3 or M74. 14. Remove the front propeller shaft by disconnecting the front propeller shaft from the transmission pinion yoke, w/ RPO MW3 or M74. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement - One Piece > Page 7542 1. Install the front propeller shaft by sliding the front propeller shaft into the transmission or the transfer case, w/o RPO MW3 or M74. 2. Install the front propeller shaft to the transmission pinion yoke, w/ RPO MW3 or M74. 3. Install the yoke retainers and the bolts, w/ RPO MW3 or M74. Important: ^ Align the reference marks made during removal. ^ Tighten the bolts until snug. Do not torque the bolts at this time. 4. Install the center bearing support (2). 5. Install the center bearing support nuts. ^ Tighten the bearing support nuts to 40 Nm (30 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the yoke retainer bolts, w/ RPO MW3 or M74. ^ Tighten the yoke retainer bolts to 25 Nm (18 ft. lbs.). 7. Inspect the splines of the front propeller shaft stub shaft for a sufficient coating of grease. If the splines of the stub shaft does not have a sufficient coating of grease, lubricate the shaft with chassis grease (GM P/N 12377985 or equivalent). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement - One Piece > Page 7543 8. Install the boot (3) and two new clamps (2) onto the front propeller shaft stub shaft (4), if applicable. 9. Install the rear propeller shaft slip yoke onto the front propeller shaft stub shaft.Mate the missing tooth in the yoke with the bridged tooth on the splined shaft. 10. Install the rear propeller shaft onto the rear axle pinion yoke.Align the reference marks made during removal. 11. Install the yoke retainers (2) and the bolts (1). ^ Tighten the yoke retainer bolts to 25 Nm (18 ft. lbs.). 12. Using the J 43218, crimp the boot clamps until the dimensions shown are obtained. 13. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement - One Piece > Page 7544 Drive/Propeller Shaft: Service and Repair Propeller Shaft Replacement - Front Propeller Shaft Replacement - Front ^ Tools Required J 43218 Clamp Pliers - Narrow Jaw Removal Procedure Important: Before disassembly, observe and accurately reference mark all driveline components relative to the propeller shaft and axles. These items include the following components: ^ The propeller shafts ^ The wheel drive shafts ^ The pinion flanges ^ The output shafts Assemble all components in the exact relationship to each other as they were prior to removal. Observe all published specifications and torque values, and any measurements obtained prior to disassembly. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield, if equipped. 3. Remove the rear propeller shaft boot clamp (4) by prying up the exposed end of the clamp with a flat-bladed tool. 4. Reference mark the relationship of the propeller shaft to the front axle pinion yoke. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement - One Piece > Page 7545 5. Remove the bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1). 6. Disconnect the propeller shaft (2) from the front axle pinion yoke (1). Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Notice: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. Important: Do not drop the bearing cap assemblies of the yoke end. 7. Disconnect the boot from the groove on the OD of the transfer case output shaft. 8. Remove the propeller shaft from the transfer case output shaft by sliding the propeller shaft forward. Installation Procedure 1. Inspect the splines of the transfer case output shaft for a sufficient coating of lubricant. If the output shaft does not have a sufficient coating of lubricant, lubricate the shaft with grease, GM P/N 12345879 (Canadian P/N 10953511) or equivalent lubricant meeting GM Specification 9985830. 2. Install a new clamp onto the propeller shaft boot. 3. Install the propeller shaft splines into the transfer case output shaft. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Replacement - One Piece > Page 7546 4. Install the propeller shaft (5) to the front axle pinion yoke (1). Align the reference marks made during removal. 5. Install the yoke retainers (7) and the bolts (6). ^ Tighten the yoke retainer bolts to 25 Nm (18 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the boot onto the transfer case output shaft until the boot snaps into the groove on the output shaft. 7. Crimp the rear propeller shaft boot clamp using the J 43218 until the dimensions shown are obtained. 8. Install the transfer case shield, if equipped. 9. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Page 7547 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises Slip Yoke: Customer Interest Driveline - Bump/Clunk/Squawking Noises Bulletin No.: 01-04-17-004B Date: January 05, 2005 TECHNICAL Subject: Clunk, Bump or Squawk when Vehicle Comes to Complete Stop or Accelerating from Complete Stop (Replace Rear Drive Shaft Nickel-Plated Slip Yoke) Models Supercede: This bulletin is being revised to add Cadillac Escalade (Old Style) to the Models section. Please discard Corporate Bulletin Number 01-04-17-004A (Section 04 - Driveline/Axle). Condition Some customers may comment on a clunk, bump or squawk noise when the vehicle comes to a stop or when accelerating from a complete stop. Cause A slip/stick condition between the transfer case output shaft and the driveshaft slip yoke may cause this condition. Diagnostic Tips There are several resources in the electronic Service Information System which can provide the technician with information on diagnosis and repair of clunk conditions, and fix the customer's vehicle right the first time without unnecessary parts replacement. Some of the documents available in SI include: ^ Symptoms - Propeller Shaft Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 7556 ^ Knock or Clunk Noise ^ Rear Drive Axle Noises (SI Document ID #700580) ^ Launch Shudder/Vibration on Acceleration (Replace Propeller Shaft and Install a New Pinion Flange/Seal), Bulletin # 02-04-17-001 ^ Information on 2-3 Upshift or 3-2 Downshift Clunk Noise, Bulletin # 01-07-30-042 ^ Driveline Clunk When Stopping (Reprogram Powertrain Control Module (PCM), Bulletin # 03-07-30-028 Correction Replace the rear drive shaft slip yoke with a new nickel-plated slip yoke. See the parts table below. Follow the service procedure below. 1. Raise the vehicle on a hoist. 2. Reference mark the propeller shaft to the pinion flange connection. Important: Do not pound on the propeller shaft yoke ears. Never pry or place any tool between a yoke and a universal joint. 3. Remove the bolts and the yoke retainers from the pinion flange. 4. Slide the propeller shaft forward and out of the rear pinion flange. 5. Lower the rear of the propeller shaft and pull the driveshaft out of the transfer case. Note: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 6. Support the propeller shaft in a line horizontal with the table of a press. Important: Remove the front slip yoke and the universal joint together. The new nickel-plated slip yoke comes with a new universal joint. 7. Disassemble the snap rings by pinching the ends together with a pair of pliers. 8. If the ring does not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the pressure from the ring. 9. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 in) hex head socket or a 27 mm (1-1/16 in) socket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 7557 10. Place the J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 11. If you do not completely remove the bearing cup, lift the cross and insert the J 9522-5 between the seal and the bearing cup you are removing. Continue pressing the bearing cup out of the yoke. 12. Rotate the propeller shaft. Press the opposite bearing cup out of the drive shaft yoke. 13. Remove the old slip yoke and universal joint. 14. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 15. Inspect the bearing cup bores for burrs or imperfections. 16. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing into place or prevent the bearing retainers from properly seating. 17. Install the new nickel-plated slip yoke and universal joint. See parts table below for parts information. 18. Remove the bearing cups from the universal joint. 19. Assemble one bearing cup part way into one side of the yoke. Turn the yoke ear toward the bottom. 20. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 7558 21. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 22. Install the opposite bearing cup part way into the yoke ear. 23. Ensure that the trunnions start straight and true into both bearing cups. 24. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for free unbinding movement of the trunnions in the bearing cups. Important: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for misalignment in the bearing cup. 25. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup. 26. Assemble the bearing retainer in the retainer groove. 27. Continue pressing until both retainers can be snapped into place. 28. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a soft-faced dead blow hammer. 29. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so that the snap ring seats in the bearing cup groove. 30. Install the slip yoke onto the output shaft in the transfer case. 31. Align the reference marks on the pinion flange and the propeller shaft. 32. Install the yoke retainers and bolts. Tighten Tighten the yoke retainer bolts to 25 N.m (19 lb ft). 33. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 7559 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 7560 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 7561 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 7562 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 7563 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 7564 Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 7565 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises Slip Yoke: All Technical Service Bulletins Driveline - Bump/Clunk/Squawking Noises Bulletin No.: 01-04-17-004B Date: January 05, 2005 TECHNICAL Subject: Clunk, Bump or Squawk when Vehicle Comes to Complete Stop or Accelerating from Complete Stop (Replace Rear Drive Shaft Nickel-Plated Slip Yoke) Models Supercede: This bulletin is being revised to add Cadillac Escalade (Old Style) to the Models section. Please discard Corporate Bulletin Number 01-04-17-004A (Section 04 - Driveline/Axle). Condition Some customers may comment on a clunk, bump or squawk noise when the vehicle comes to a stop or when accelerating from a complete stop. Cause A slip/stick condition between the transfer case output shaft and the driveshaft slip yoke may cause this condition. Diagnostic Tips There are several resources in the electronic Service Information System which can provide the technician with information on diagnosis and repair of clunk conditions, and fix the customer's vehicle right the first time without unnecessary parts replacement. Some of the documents available in SI include: ^ Symptoms - Propeller Shaft Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 7571 ^ Knock or Clunk Noise ^ Rear Drive Axle Noises (SI Document ID #700580) ^ Launch Shudder/Vibration on Acceleration (Replace Propeller Shaft and Install a New Pinion Flange/Seal), Bulletin # 02-04-17-001 ^ Information on 2-3 Upshift or 3-2 Downshift Clunk Noise, Bulletin # 01-07-30-042 ^ Driveline Clunk When Stopping (Reprogram Powertrain Control Module (PCM), Bulletin # 03-07-30-028 Correction Replace the rear drive shaft slip yoke with a new nickel-plated slip yoke. See the parts table below. Follow the service procedure below. 1. Raise the vehicle on a hoist. 2. Reference mark the propeller shaft to the pinion flange connection. Important: Do not pound on the propeller shaft yoke ears. Never pry or place any tool between a yoke and a universal joint. 3. Remove the bolts and the yoke retainers from the pinion flange. 4. Slide the propeller shaft forward and out of the rear pinion flange. 5. Lower the rear of the propeller shaft and pull the driveshaft out of the transfer case. Note: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 6. Support the propeller shaft in a line horizontal with the table of a press. Important: Remove the front slip yoke and the universal joint together. The new nickel-plated slip yoke comes with a new universal joint. 7. Disassemble the snap rings by pinching the ends together with a pair of pliers. 8. If the ring does not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the pressure from the ring. 9. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 in) hex head socket or a 27 mm (1-1/16 in) socket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 7572 10. Place the J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 11. If you do not completely remove the bearing cup, lift the cross and insert the J 9522-5 between the seal and the bearing cup you are removing. Continue pressing the bearing cup out of the yoke. 12. Rotate the propeller shaft. Press the opposite bearing cup out of the drive shaft yoke. 13. Remove the old slip yoke and universal joint. 14. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 15. Inspect the bearing cup bores for burrs or imperfections. 16. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing into place or prevent the bearing retainers from properly seating. 17. Install the new nickel-plated slip yoke and universal joint. See parts table below for parts information. 18. Remove the bearing cups from the universal joint. 19. Assemble one bearing cup part way into one side of the yoke. Turn the yoke ear toward the bottom. 20. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 7573 21. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 22. Install the opposite bearing cup part way into the yoke ear. 23. Ensure that the trunnions start straight and true into both bearing cups. 24. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for free unbinding movement of the trunnions in the bearing cups. Important: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for misalignment in the bearing cup. 25. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup. 26. Assemble the bearing retainer in the retainer groove. 27. Continue pressing until both retainers can be snapped into place. 28. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a soft-faced dead blow hammer. 29. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so that the snap ring seats in the bearing cup groove. 30. Install the slip yoke onto the output shaft in the transfer case. 31. Align the reference marks on the pinion flange and the propeller shaft. 32. Install the yoke retainers and bolts. Tighten Tighten the yoke retainer bolts to 25 N.m (19 lb ft). 33. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 7574 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 7575 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 7576 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 7577 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 7578 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 7579 Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 7580 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring Universal Joint: Service and Repair Universal Joint Replacement - Nylon Injected Ring Universal Joint Replacement - Nylon Injected Ring ^ Tools Required J 9522-3 U Joint Bearing Separator - J 9522-5 U Joint Bearing Spacer Remover Disassembly Procedure 1. Support the propeller shaft in a line horizontal with the table of a press. Notice: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 2. Mark the propeller shaft as to which end is the transmission end and which end goes to the rear axle. 3. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1 1/8 inch) socket. 4. In order to shear the plastic retaining ring on the bearing cup, place J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 5. If you do not completely remove the bearing cup, lift the cross and insert J 9522-5 between the seal and the bearing cup you are removing. Continue to press the bearing cup out of the yoke. 6. Rotate the propeller shaft. Press the opposite bearing cup out of the yoke. 7. Mark the orientation of the slip yoke to the tube for proper reassembly. 8. Remove the cross from the yoke. 9. Remove the remaining universal joint parts from the yoke. If you are replacing the front universal joint, remove the bearing cups in the slip yoke in the same manner. 10. Inspect the retaining ring grooves for plastic. 11. Inspect the bearing cup bores in the yoke ears for burrs or imperfections. 12. Clean the remains of the sheared plastic bearing retainers from the grooves in the yoke. 13. The sheared plastic may prevent the bearing cups from pressing into place and thus prevent the bearing retainers from properly seating. Assembly Procedure 1. Remove the bearing cups from the universal joint. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 7585 2. Assemble 1 bearing cup part way into 1 side of the yoke. 3. Turn the yoke ear toward the bottom. 4. Assemble the cross into the yoke so the trunnion seats freely into the bearing cup. 5. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 6. Assemble the opposite bearing cup part way into the yoke ear. 7. Ensure that the trunnions start straight and true into both bearing cups. 8. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for a free unbinding movement of the trunnions in the bearing cups. 9. Press the bearing cup into the yoke until the bearing retainer groove clears the inside of the yoke. Important: If there seems to be a hangup or binding, stop pressing, and inspect the needle bearings for misalignment in the bearing cup. 10. Assemble the bearing retainer in the retainer groove. 11. Continue pressing until you can snap both retainers into place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 7586 12. If seating the retainer is difficult, spring the yoke slightly with a firm blow from a dead blow hammer. 13. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so the snap ring seats in the bearing cup groove. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 7587 Universal Joint: Service and Repair Universal Joint Replacement - External Snap Ring Universal Joint Replacement - External Snap Ring ^ Tools Required J 9522-3 U-Joint Bearing Separator - J 9522-5 U-Joint Bearing Spacer Remover Disassembly Procedure Notice: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 1. Support the propeller shaft in a line horizontal with the table of a press. 2. Mark the propeller shaft in order to show which end connects to the transmission and which end goes to the rear axle. 3. Disassemble the snap rings by pinching the ends together with a pair of pliers. 4. If the ring does not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the pressure from the ring. 5. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 inch) hex head socket or a 27 mm (1-1/16 inch) socket. 6. Place J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 7. If you do not completely remove the bearing cup, lift the cross and insert J 9522-5 between the seal and the bearing cup you are removing. Continue pressing the bearing cup out of the yoke. 8. Rotate the propeller shaft . Press the opposite bearing cup out of the yoke. 9. Mark the orientation of the slip yoke to the tube for proper reassembly. 10. Remove the cross from the yoke. 11. Remove the remaining universal joint parts from the yoke. 12. If you are replacing the front universal joint, remove the bearing cups in the slip yoke in the same manner. 13. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 14. Inspect the bearing cup bores for burrs or imperfections. 15. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing into place or prevent the bearing retainers from properly seating. Assembly Procedure 1. Remove the bearing cups from the universal joint. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 7588 2. Assemble 1 bearing cup part way into 1 side of the yoke. Turn the yoke ear toward the bottom. 3. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup. 4. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 5. Install the opposite bearing cup part way into the yoke ear. 6. Ensure that the trunnions start straight and true into both bearing cups. 7. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for free unbinding movement of the trunnions in the bearing cups. 8. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup. Important: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for misalignment in the bearing cup. 9. Assemble the bearing retainer in the retainer groove. 10. Continue pressing until both retainers can be snapped into place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 7589 11. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a dead blow hammer. 12. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so that the snap ring seats in the bearing cup groove. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Flywheel to Crankshaft Flex Plate: Specifications Flywheel to Crankshaft Flywheel Bolts First Pass ............................................................................................................................................. .................................................. 79 Nm (58 ft. lbs.) Second Pass ....................................................... ................................................................................................................................................ 60 degrees Final Pass .............................................................................................................................. ....................................................... an additional 60 degrees Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Flywheel to Crankshaft > Page 7594 Flex Plate: Specifications Flywheel to Converter Automatic Transmission - 4L80-E/4L85-E Flywheel to Converter .......................................................................................................................... .................................................... 43 Nm (32 ft. lbs.) Automatic Transmission - Allison Torque Converter to Flywheel Bolts ......................................................................................................................................................... 60 Nm (44 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 7595 Flex Plate: Service and Repair Engine Flywheel Replacement (Automatic Transmission) ^ Tools Required J 44643 Flywheel Holding Tool - J 45059 Angle Meter Removal Procedure 1. Remove the transmission. 2. Install J 44643 in order to hold the flywheel. 3. Caution: When removing, handling or installing this component wear protective gloves. The sharp edges on the component may be very sharp and may cause injury. Remove and discard the flywheel bolts. 4. Remove the flywheel washer and flywheel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 7596 Installation Procedure Caution: When removing, handling or installing this component wear protective gloves. The sharp edges on the component may be very sharp and may cause injury. 1. Important: When installing the flywheel, ensure that the tapered side of the teeth are facing the starter. Install the flywheel. 2. Install the flywheel washer with the beveled side facing the engine. Notice: Refer to Fastener Notice in Service Precautions. 3. Notice: This component uses bolts with a preapplied molybdenum disulfide coating for thread lubrication. Do not remove the coating or use any additional lubricant. Improperly lubricated threads will adversely affect the bolt torque and clamp load. Improper bolt torque and clamp load can lead to engine damage. Install NEW flywheel bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 7597 4. Tighten the flywheel bolts in the proper sequence. 1. Tighten the bolts a first pass to 79 Nm (58 ft. lbs.). 2. Tighten the bolts a second pass to 60 degrees using J 45059. 3. Tighten the bolts a final pass an additional 60 degrees using J 45059. 5. Remove J 44643 from the flywheel. 6. Install the transmission. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-31-006B > Jan > 07 > M/T - Shifter Vibration/Growl/Rattle Depressing Clutch Flywheel: Customer Interest M/T - Shifter Vibration/Growl/Rattle Depressing Clutch Bulletin No.: 04-07-31-006B Date: January 23, 2007 TECHNICAL Subject: Excessive Shifter and/or Engine Vibration, Bearing Growl and/or Rattle Type Noise While Depressing or Releasing Clutch Pedal (Replace Flywheel and Flywheel Mounting Bolts) Models: 2001-2005 Chevrolet Silverado 2001-2005 GMC Sierra with 6.6L Duramax(TM) Diesel (RPOs LB7, LLY) and Manual Transmission (RPO ML6) Supercede: This bulletin is being revised to update the part number for the dual-mass flywheel and remove the VIN breakpoints. Please discard Corporate Bulletin Number 04-07-31-006A (Section 07 Transmission/Transaxle). The VIN breakpoints were no longer needed because the new dual-mass flywheel will benefit all applications through model year 2005. To improve high mileage durability related to the issue outlined in this bulletin, a new Dual-Mass Flywheel, P/N 24238864, was released with the same balance characteristics as the pre-2006 flywheel, with 12 rivets instead of six. Condition Some customers may comment on a bearing growl or rattle-type noise while depressing or releasing the clutch pedal. Some customers may comment on excessive shifter or engine vibration. In some cases, the excessive vibration may result in an injector balance rate fluctuation condition. Cause The steel clutch thrust washer may wear down the flywheel bushing prematurely, causing an excessive vibration condition. Diagnostic Tips The bearing growl/rattle-type noise and or vibration is eliminated with the clutch fully engaged or disengaged. Correction Replace the flywheel assembly with a Dual-Mass Flywheel, P/N 24238864. Refer to the applicable SI procedure below. The eight flywheel mounting bolts, P/N 97226124, must be replaced when service requires removal or replacement of the flywheel. Engine Mechanical - 6.6L (LB7) - Engine Flywheel Replacement - Manual Transmission. Engine Mechanical - 6.6L (LLY) - Engine Flywheel Replacement - Manual Transmission. Parts Information Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-31-006B > Jan > 07 > M/T - Shifter Vibration/Growl/Rattle Depressing Clutch > Page 7606 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-31-006B > Jan > 07 > M/T - Shifter Vibration/Growl/Rattle Depressing Clutch Flywheel: All Technical Service Bulletins M/T - Shifter Vibration/Growl/Rattle Depressing Clutch Bulletin No.: 04-07-31-006B Date: January 23, 2007 TECHNICAL Subject: Excessive Shifter and/or Engine Vibration, Bearing Growl and/or Rattle Type Noise While Depressing or Releasing Clutch Pedal (Replace Flywheel and Flywheel Mounting Bolts) Models: 2001-2005 Chevrolet Silverado 2001-2005 GMC Sierra with 6.6L Duramax(TM) Diesel (RPOs LB7, LLY) and Manual Transmission (RPO ML6) Supercede: This bulletin is being revised to update the part number for the dual-mass flywheel and remove the VIN breakpoints. Please discard Corporate Bulletin Number 04-07-31-006A (Section 07 Transmission/Transaxle). The VIN breakpoints were no longer needed because the new dual-mass flywheel will benefit all applications through model year 2005. To improve high mileage durability related to the issue outlined in this bulletin, a new Dual-Mass Flywheel, P/N 24238864, was released with the same balance characteristics as the pre-2006 flywheel, with 12 rivets instead of six. Condition Some customers may comment on a bearing growl or rattle-type noise while depressing or releasing the clutch pedal. Some customers may comment on excessive shifter or engine vibration. In some cases, the excessive vibration may result in an injector balance rate fluctuation condition. Cause The steel clutch thrust washer may wear down the flywheel bushing prematurely, causing an excessive vibration condition. Diagnostic Tips The bearing growl/rattle-type noise and or vibration is eliminated with the clutch fully engaged or disengaged. Correction Replace the flywheel assembly with a Dual-Mass Flywheel, P/N 24238864. Refer to the applicable SI procedure below. The eight flywheel mounting bolts, P/N 97226124, must be replaced when service requires removal or replacement of the flywheel. Engine Mechanical - 6.6L (LB7) - Engine Flywheel Replacement - Manual Transmission. Engine Mechanical - 6.6L (LLY) - Engine Flywheel Replacement - Manual Transmission. Parts Information Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-31-006B > Jan > 07 > M/T - Shifter Vibration/Growl/Rattle Depressing Clutch > Page 7612 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Flywheel: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Flywheel: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7618 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Flywheel: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7619 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Flywheel: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7620 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Flywheel: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7626 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Flywheel: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7627 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Flywheel: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7628 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Technical Service Bulletins > Page 7629 Flywheel: Specifications Flywheel Bolts First Pass ............................................................................................................................................. .................................................. 79 Nm (58 ft. lbs.) Second Pass ....................................................... ................................................................................................................................................ 60 degrees Final Pass .............................................................................................................................. ........................................................... additional 60 degrees Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Technical Service Bulletins > Page 7630 Flywheel: Service and Repair Engine Flywheel Replacement (Manual Transmission) ^ Tools Required J 44643 Flywheel Holding Tool - J 45059 Angle Meter Removal Procedure 1. Remove the clutch. 2. Remove the starter motor. 3. Install J 44643 in order to hold the flywheel. 4. Important: DO NOT use the clutch pressure plate bolts. Use a bolt of the correct thread and length that protrudes enough to use a pry bar. Install 2 bolts into the clutch pressure plate mounting hole 180 degrees apart. 5. Using a long pry bar, turn the secondary ring of the dual mass flywheel clockwise until the flywheel mounting bolts can be accessed. It may be required to turn the secondary ring past the bolt holes in order to compensate the spring tension. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Technical Service Bulletins > Page 7631 6. Remove and discard the flywheel bolts. 7. Remove the flywheel. 8. If necessary, remove the pilot bearing. 9. If required, clean and inspect the flywheel. Installation Procedure Caution: When removing, handling or installing this component wear protective gloves. The sharp edges on the component may be very sharp and may cause injury. 1. If necessary, install a NEW pilot bearing. 2. Caution: When removing, handling or installing this component wear protective gloves. The sharp edges on the component may be very sharp and may cause injury. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Technical Service Bulletins > Page 7632 Important: When installing the flywheel, ensure that the tapered side of the teeth are facing the starter. Install the flywheel. 3. Notice: This component uses bolts with a preapplied molybdenum disulfide coating for thread lubrication. Do not remove the coating or use any additional lubricant. Improperly lubricated threads will adversely affect the bolt torque and clamp load. Improper bolt torque and clamp load can lead to engine damage. Loosely install NEW flywheel bolts. 4. Notice: Refer to Fastener Notice in Service Precautions. Tighten the flywheel bolts in the proper sequence. 1. Tighten the bolts a first pass to 79 Nm (58 ft. lbs.). 2. Tighten the bolts a second pass to 60 degrees using J 45059. 3. Tighten the bolts a final pass an additional 60 degrees using J 45059. 5. Install the starter motor. 6. Install the clutch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Maintenance Indicator - A/T > Component Information > Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation PRNDL DISPLAY The IPC displays the selected gear position as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the gear position. The PRNDL display blanks if: - The IPC receives a class 2 message indicating the park position and the column park switch indicates a position other than park, open input. - The IPC detects a loss of class 2 communications with the PCM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades Fluid - M/T: Customer Interest Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 7650 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 7651 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 7652 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 7653 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 7654 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 7655 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Customer Interest: > 06-06-04-036D > Jun > 07 > Diesel Engine - Runs Hot Towing or Pulling Grades > Page 7656 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine Runs Hot Towing or Pulling Grades Fluid - M/T: All Technical Service Bulletins Diesel Engine - Runs Hot Towing or Pulling Grades Bulletin No.: 06-06-04-036D Date: June 04, 2007 TECHNICAL Subject: Engine Overheats or Runs Hot in High Ambient Temperature When Towing or Hauling on Long Inclines (Install 2006 Air Cleaner Assembly) Models: 2004-2005 Chevrolet Silverado 2500/3500 Series 2004-2005 GMC Sierra 2500/3500 Series with 6.6L Diesel Engine VIN 2 - RPO LLY) Built From January 1, 2004 Through 2005 End of Production Supercede: This bulletin is being revised to clarify steps 10 and 11 and the illustration in step 10 of the procedure. Please discard Corporate Bulletin Number 06-06-04-036C (Section 06 Engine/Propulsion System). Condition Some customers may comment that while towing a trailer, or if the vehicle is loaded on a long upgrade climb and high ambient temperatures, the Driver Information Center states Engine Coolant Hot, the engine overheats and there is a loss of power and air conditioning. Cause This condition may be caused by any of the following possibilities: Installation of an aftermarket grille. A plugged charge air cooler. Fan clutch not operating properly. Drive belt slip. An overfilled transmission. Turbocharger not operating properly. A plugged air filter. Correction Inspect the following areas FIRST. Inspect for changes to the air intake area or for aftermarket grille accessories. Make sure all air dams are in place and not modified. Remove any aftermarket grille or accessories that may restrict air flow. Visually inspect the Charge Air Cooler (CAC) to insure that it is not plugged externally. Use the Special Tool J 46091 to ensure that all pipe connections are properly sealed and the CAC does not have a leak. Monitor the fan clutch operation and complete SI Diagnostics for Fan Clutch Diagnosis. If the fan seems to be cycling on and off when the engine RPMs are above 2800, this could indicate a belt slip condition. Monitor the actual and desired turbo vane position to verify that the turbocharger is performing properly. Inspect the transmission fluid level. An overfilled transmission can add to heat levels in the cooling system. Inspect the air induction system. Ensure that the filter is in good condition and is properly installed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine Runs Hot Towing or Pulling Grades > Page 7662 If no issues were found after the above inspections, install a 2006 air cleaner system using the following procedure. Disconnect the mass air flow sensor electrical connector and remove the sensor from the air outlet duct. Loosen the clamps and remove the air cleaner outlet duct. Remove the air cleaner assembly. Grasp the air filter assembly and pull up on the assembly in order to disengage the retaining pins from the grommets. Remove the five 10 mm bolts and the tray. Remove the insulation on the inner right fender. With the wheel turned to the right, measure from the corner of the wheel liner over 231 mm (9 in) and up 45 mm (1.8 in) as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine Runs Hot Towing or Pulling Grades > Page 7663 Measure up 75 mm (3 in) from the bottom of the liner and measure the lip of the liner 20 mm (0.8 in) as seen in the illustration above. With a 5/16 or 8 mm drill bit, drill two holes though the wheelhouse liner. Remove the wheel liner fasteners and pull the liner back. Install the new baffle assembly intake air (lower baffle) to the fender with the two push-in fasteners. The arrows in the illustration above point to where the push-in fasteners will go. Install the new inner fender air duct by inserting the duct between the inner and outer sheet metal. The duct has a nipple on the side and will snap in place on the inner sheet metal of the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine Runs Hot Towing or Pulling Grades > Page 7664 Install the wheel liner and fasteners. Install the two bolts that retains the baffle assembly intake air to the wheel liner. Install the plastic closeout panel on the radiator support. Install the air cleaner bracket, bolts and new tray. Tighten Tighten the bolts to 9 N.m (80 lb in). Install the air cleaner assembly. Push down on the assembly in order to secure it to the bracket. Do not attempt to cut off the outlet duct on the vehicle or debris could enter the turbo and cause damage. Measure back from the Caution label on the air cleaner outlet duct 52 mm (2 in) on the existing duct, and cut the duct. Measure from the side that was cut, 13 mm (1/2-in), and drill a 5/32 or 5 mm hole on each side of the duct and install rivets as seen in the illustration above. Connect the two ducts together. Install the air cleaner outlet duct to the air cleaner assembly and the turbo inlet. It may be necessary to reposition the clamp on the air cooler outlet duct. Tighten Tighten the three clamps to 4 N.m (35 lb in). Tighten Tighten the air cooler outlet duct clamp to 6 N.m (53 lb in). Install the mass air flow sensor and connect the connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine Runs Hot Towing or Pulling Grades > Page 7665 Install the intake horizontal baffle as seen in the illustration above. Remove the right head lamp assembly. Refer to SI if necessary. With the head lamp out, clean the surface with 3M(R) General Purpose Adhesive Cleaner, or equivalent. Install the baffle intake air (foam block) on the radiator support as seen in the illustration above. Reprogram the vehicle PCM with new software. Refer to TIS for the calibration cylindrical air cleaner housing. Reposition the engine oil indicator (dipstick) tube toward the fender so it will clear the air cleaner outlet duct. If the vehicle is a 2004 or 2005 GMC Sierra, the following items will have to be installed to ensure cooler air is entering the system. Remove the left and right head lamp assembly. Refer to SI if necessary. Install the seal around the lamp with the wide part of the seal across the top of the lamp. Remove the grille. Refer to SI if necessary. Install the seals on the left and right side of the grille as seen in the illustration above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine Runs Hot Towing or Pulling Grades > Page 7666 Clean the surface of the inner right fender and install the vertical seal as seen in the illustration above. Clean the lip on the left fender and install the horizontal hood seal to the fender. Install the grille. Install the head lamps. Refer to SI if necessary. Ensure that the sealing is optimized between the air cleaner housing and the inner fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine Runs Hot Towing or Pulling Grades > Page 7667 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-06-04-036D > Jun > 07 > Diesel Engine Runs Hot Towing or Pulling Grades > Page 7668 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - M/T: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - M/T: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 7674 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - M/T: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 7675 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - M/T: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 7681 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - M/T: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 7682 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Transmission Fluid NV3500 ................................................................................................................ ............................................................................................. 2.3L (2.4 Qt) NV4500 ............................ .............................................................................................................................................................. ................... 3.8L (4.0 Qt) 6 Speed (ZF) (RPO ML6) ........................................................................... ...................................................................................................... 6.0L (6.3 Qt) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 7685 Fluid - M/T: Fluid Type Specifications Transmission Fluid 5-SPEED WITH LOW GEAR (RPO MW3) Grade ............................................................................... .............................................................................................................................. GL-4 Synthetic Viscosity .............................................................................................................................................. ..................................................................... 75W-90 5-SPEED WITHOUT LOW GEAR (RPO MG5) Fluid Type ................................................................................................................................................. Synchromesh Transmission Fluid P/N 12345349 6-SPEED Fluid Type ....................................................................................................................... Synthetic Transmission Fluid approved for Allison Transmission Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > NV 3500 Fluid - M/T: Service and Repair NV 3500 Transmission Fluid Replacement ^ Tools Required J 36511 Oil Fill/Drain Plug Hex Bit (17 MM) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Using J 36511 remove the oil fill plug. 3. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 4. Using J 36511 remove the oil drain plug. 5. Remove any old sealant from the transmission housing. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > NV 3500 > Page 7688 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil drain and fill plug threads. 2. Notice: Refer to Fastener Notice in Service Precautions. Using J 36511 install the oil drain plug. ^ Tighten the plug to 30 Nm (22 ft. lbs.). 3. Remove and drain the drain pan used to catch the used transmission fluid. 4. Fill the transmission to just below the bottom of the fill plug hole. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > NV 3500 > Page 7689 5. Using J 36511 install the oil fill plug. ^ Tighten the plug to 30 Nm (22 ft. lbs.). 6. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > NV 3500 > Page 7690 Fluid - M/T: Service and Repair NV 4500 Transmission Fluid Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the oil fill plug. 3. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 4. Remove the oil drain plug. 5. Remove any old sealant from the transmission housing. Installation Procedure 1. Apply a thin bead of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil drain and fill plug threads. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil drain plug. ^ Tighten the plug to 37 Nm (27 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > NV 3500 > Page 7691 3. Fill the transmission to just below the bottom of the fill plug hole. 4. Install the oil fill plug. ^ Tighten the plug to 37 Nm (27 ft. lbs.). 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > NV 3500 > Page 7692 Fluid - M/T: Service and Repair ZF S6-650 Transmission Fluid Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the oil fill plug. 3. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 4. Remove the oil drain plug. 5. Remove any old sealant from the transmission housing and plugs. Installation Procedure 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the treads of the oil drain and fill plugs. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the oil drain plug. ^ Tighten the plug to 35 Nm (26 ft. lbs.). 3. Fill the transmission to just below the bottom of the fill plug hole. Refer to Lubrication Specifications. 4. Install the oil fill plug. ^ Tighten the plug to 35 Nm (26 ft. lbs.). 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > NV 3500 Seals and Gaskets: Service and Repair NV 3500 Transmission Housing Oil Seal Replacement - Front Transmission Housing Oil Seal Replacement - Front Removal Procedure 1. Remove the transmission. 2. Remove the clutch actuator cylinder bolts. 3. Remove the clutch actuator cylinder. 4. Remove the input shaft bearing retainer bolts. Remove the input shaft bearing retainer. Screw 2 of the removed bolts into the threaded holes in the retainer in order to remove the retainer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > NV 3500 > Page 7697 5. Using a hammer and a punch, remove the transmission housing front oil seal from the input shaft bearing retainer. 6. Remove the old gasket material from the input shaft bearing retainer. Installation Procedure Important: Inspect the input shaft bearing retainer for any nicks or cracks that may result in a leak. Replace as necessary. 1. Position a NEW oil seal in the input shaft bearing retainer. 2. Using a suitable tool, install the oil seal. 3. Apply RTV sealer GM P/N 12345739 (Canadian P/N 10953472), or equivalent to the inside edge of the bearing retainer mating surface. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > NV 3500 > Page 7698 4. Position the input shaft bearing retainer. Align the bearing retainer oil drain hole with the drain hole in the transmission housing. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the input shaft bearing retainer bolts. ^ Tighten the bolts to 14 Nm (10 ft. lbs.). 6. Install the clutch actuator cylinder and the bolts. ^ Tighten the bolts to 8 Nm (71 inch lbs.) 7. Install the transmission. 8. Lower the vehicle. Transmission Housing Oil Seal Replacement - Rear Transmission Housing Oil Seal Replacement - Rear (4WD) ^ Tools Required J 36825 Output Shaft Oil Seal Remover - J 23907 Slide Hammer - J 36502-2A Output Shaft Oil Seal Protector - J 36502 Extension Housing Seal Installer Removal Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > NV 3500 > Page 7699 1. Remove transfer case. 2. Using J 36825 and J 23907 remove the output shaft seal. Installation Procedure 1. Position the J 36502-2A over the output shaft. 2. Using J 36502 install the NEW output shaft seal. 3. Remove the J 36502-2A from the output shaft. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > NV 3500 > Page 7700 4. Fill the space between the seal lips with grease GM P/N 1052497 or equivalent. 5. Install transfer case. 6. Check the transmission fluid level. Add as necessary. 7. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > NV 3500 > Page 7701 Seals and Gaskets: Service and Repair NV 4500 Transmission Housing Oil Seal Replacement - Front Removal Procedure ^ Tools Required J 38801 Input Shaft Seal Installer 1. Remove the transmission. 2. Remove the clutch actuator cylinder bolts. 3. Remove the clutch actuator cylinder. 4. Remove the input shaft bearing retainer bolts.Remove the input shaft bearing retainer. Screw 2 of the removed bolts into the threaded holes in the retainer in order to remove the retainer. 5. Using a hammer and a punch, remove the transmission housing front oil seal from the input shaft bearing retainer. 6. Remove the old gasket material from the input shaft bearing retainer. Installation Procedure Important: Inspect the input shaft bearing retainer for any nicks or cracks that may result in a leak. Replace as necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > NV 3500 > Page 7702 1. Position a NEW oil seal in the input shaft bearing retainer. 2. Using J 38801, install the oil seal. 3. Apply a thin bead of RTV sealer GM P/N 12345739 (Canadian P/N 10953472), or equivalent to the input shaft bearing retainer mating surface. 4. Position the input shaft bearing retainer. 5. Align the bearing retainer oil drain hole at the top dead center position. 6. Apply threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the input shaft bearing retainer bolts. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the input shaft bearing retainer bolts. ^ Tighten the bolts to 22 Nm (16 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > NV 3500 > Page 7703 8. Install the clutch actuator cylinder and bolts. ^ Tighten the bolts to 8 Nm (71 inch lbs.) 9. Install the transmission. 10. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > NV 3500 > Page 7704 Seals and Gaskets: Service and Repair ZF S6-650 Transmission Input Shaft Seal Replacement Transmission Input Shaft Seal Replacement ^ Tools Required J 23907 Slide Hammer - J 44748 Seal Remover - J 44731 Input Shaft Oil Seal Installer Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the rear propeller shaft. 3. Remove the transmission. Important: The clutch actuator hose can remain connected to the clutch actuator. Disconnecting the hose from the clutch actuator will allow the hydraulic fluid to drain from the hydraulic system. 4. Remove the clutch actuator cylinder bolts. Do not disconnect the hose from the actuator. 5. Remove the clutch actuator cylinder. 6. Remove the front oil seal using J 23907 (2) and J 44748 (1). Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > NV 3500 > Page 7705 1. Position the NEW seal in the front case with the part number facing out. 2. Using J 44731 install the input shaft seal. 3. Notice: Refer to Fastener Notice in Service Precautions. Position the clutch actuator cylinder. 4. Install the clutch actuator cylinder bolts. ^ Tighten the bolts to 8 Nm (71 inch lbs.). 5. Install the transmission. 6. Install the rear propeller shaft. 7. Check the transmission fluid level. Add if necessary. 8. Lower the vehicle. Transmission Output Shaft Seal Replacement Transmission Output Shaft Seal Replacement ^ Tools Required J 6125-1B Slide Hammer - J 44732 Output Shaft Oil Seal Installer - J 23129 Universal Seal Remover - J 8614-01 Pinion Flange Holder Removal Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > NV 3500 > Page 7706 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the rear propeller shaft. 3. Using the J 8614-01 to hold the transmission yoke, remove and discard the yoke nut. 4. Remove the yoke. 5. Using J 6125-1B (1) and J 23129 (2), remove the rear oil seal. Installation Procedure Important: The J 44732 will set the oil seal to the proper depth. Failure to use the J 44732 will cause improper installation of the oil seal. 1. Using J 44732 install the rear oil seal. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > NV 3500 > Page 7707 2. Install the yoke. 3. Use the J 8614-01 in order to hold the yoke. Notice: Refer to Fastener Notice in Service Precautions.. 4. Install a NEW yoke nut. ^ Tighten the nut to 330 Nm (244 ft. lbs.). 5. Install the rear propeller shaft. 6. Check the transmission fluid level. Add if necessary. 7. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > NV 3500 Shifter M/T: Service and Repair NV 3500 Shift Lever Assembly Replacement Removal Procedure Important: ^ Ensure that the control lever is positioned into the mechanical third or fourth gear prior to removal of the shift lever from the transmission. The transmission must remain in this state when the shift lever is removed. ^ Do not disassemble the transmission shift lever. Internal parts for this shift lever are not available. Opening the shift lever voids the warranty. ^ When removing the shift lever from the transmission, use the exposed bolts on the base of the lever. 1. Remove the control lever and boot. 2. Remove the boot. 3. Remove the shift lever bolts. 4. Remove the shift lever and seal. 5. Remove the shift lever insulator. Installation Procedure 1. Install a NEW shift lever insulator. 2. Install the shift lever seal and lever. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the shift lever bolts. ^ Tighten the bolts to 20 Nm (15 ft. lbs.). 4. Install the boot. 5. Install the control lever and boot. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > NV 3500 > Page 7712 Shifter M/T: Service and Repair NV 4500 Shift Lever Assembly Replacement Removal Procedure Important: ^ Ensure that the control lever is positioned into the mechanical third or fourth gear prior to removal of the shift lever from the transmission. The transmission must remain in this state when the shift lever is removed. ^ Do not disassemble the transmission shift lever. Internal parts for this shift lever are not available. Opening the shift housing lever voids the warranty. ^ When removing the shift lever from the transmission, use the exposed bolts on the base of the lever. 1. Remove the control lever and boot. 2. Remove the transmission support. 3. Lower the transmission slightly to access to insulator. 4. Cut one side of the insulator in order to remove it. Remove the insulator. 5. Remove the shift lever and seal. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > NV 3500 > Page 7713 1. Install the shift lever seal and lever. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the shift lever bolts. ^ Tighten the bolts to 20 Nm (15 ft. lbs.). 3. Install the insulator. 4. Raise the transmission. 5. Install the transmission support. 6. Install the control lever and boot. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > NV 3500 > Page 7714 Shifter M/T: Service and Repair ZF S6-650 Shift Lever Assembly Replacement Removal Procedure Important: ^ Ensure that the control lever is positioned into the mechanical third or fourth gear prior to removal of the shift lever assembly from the transmission. The transmission must remain in this state when the shift lever assembly is removed. ^ When removing the shift lever assembly from the transmission, use the exposed bolts on the base of the shift lever assembly. 1. Remove the control lever and boot. 2. With a flat-bladed tool, pull back the insulator between the body and transmission to access the shift tower bolts. 3. Remove the boot. 4. Remove the shift lever bolts. 5. Remove the shift lever and seal. 6. Remove the shift lever insulator. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > NV 3500 > Page 7715 1. Install a NEW shift lever insulator, if required. 2. Apply gasket maker GM P/N 12378517 or equivalent to the surface of the control lever assembly. 3. Push the shift lever assembly back through the insulator, position and turn the shift lever assembly back into place. 4. With a flat tool pull back the insulator between the body and transmission to install the shift lever assembly bolts. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the shift lever assembly bolts. ^ Tighten the bolts to 23 Nm (17 ft. lbs.). 6. Install the control lever and boot. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Boot, M/T > Component Information > Service and Repair > NV 3500 Shift Boot: Service and Repair NV 3500 Control Lever and/or Boot Replacement Removal Procedure 1. Important: DO NOT move the shift lever assembly adjustment nut if replacing the control lever. Remove the control lever. 2. Remove the control lever boot retainer plastic retainers, if necessary. 3. Remove the control lever boot retainer, if necessary. 4. Remove the control lever boot screws, if necessary. 5. Remove the control lever boot, if necessary. 6. Remove the control lever insulator, if necessary. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Boot, M/T > Component Information > Service and Repair > NV 3500 > Page 7721 1. Install the control lever insulator, if removed. 2. Install the control lever boot to the control lever, if removed. 3. Install the control lever. 4. If alignment of the control lever is necessary, or if the shift lever assembly was replaced perform the following: 1. The nut must be seated at the bottom of the thread runout on the shift lever. 2. Seat the control lever against the shift lever assembly adjustment nut. 3. Back the control lever off the nut in order to align the index mark on the control lever perpendicular to the edge of the control lever boot retainer. 4. Ensure that the index mark is located on the passenger side and that the shift pattern is aligned parallel to the vehicle centerline or rotated no more than 6 degrees clockwise. 5. Notice: Refer to Fastener Notice in Service Precautions. Hold the control lever and tighten the shift lever assembly nut against the control lever. ^ Tighten the nut to 37 Nm (27 inch lbs.). 5. Seat the control lever boot to the floor. 6. Install the control lever boot screws, if removed. ^ Tighten the screws to 1.6 Nm (14 inch lbs.). 7. Install the control lever boot retainer, if removed. 8. Install the control lever boot retainer plastic retainers, if removed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Boot, M/T > Component Information > Service and Repair > NV 3500 > Page 7722 Shift Boot: Service and Repair NV 4500 Control Lever and/or Boot Replacement Removal Procedure 1. Important: DO NOT move the shift lever assembly adjustment nut if replacing the control lever. Remove the control lever. 2. Remove the control lever boot retainer plastic retainers, if necessary. 3. Remove the control lever boot retainer, if necessary. 4. Remove the control lever boot screws, if necessary. 5. Remove the control lever boot, if necessary. 6. Remove the control lever insulator, if necessary. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Boot, M/T > Component Information > Service and Repair > NV 3500 > Page 7723 1. Install the control lever insulator, if removed. 2. Install the control lever boot to the control lever, if removed. 3. Install the control lever. 4. If alignment of the control lever is necessary, or if the shift lever assembly was replaced perform the following: 1. The nut must be seated at the bottom of the thread runout on the shift lever. 2. Seat the control lever against the shift lever assembly adjustment nut. 3. Back the control lever off the nut in order to align the index mark on the control lever perpendicular to the edge of the control lever boot retainer. 5. Ensure that the index mark is located on the passenger side and that the shift pattern is aligned parallel to the vehicle centerline or rotated no more than 6 degrees clockwise. 6. Notice: Refer to Fastener Notice in Service Precautions. Hold the control lever and tighten the shift lever assembly nut against the control lever. ^ Tighten the nut to 37 Nm (27 ft. lbs.). 7. Seat the control lever boot to the floor. 8. Install the control lever boot screws, if removed. ^ Tighten the screws to 1.6 Nm (14 inch lbs.). 9. Install the control lever boot retainer, if removed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Boot, M/T > Component Information > Service and Repair > NV 3500 > Page 7724 Shift Boot: Service and Repair ZF S6-650 Control Lever and/or Boot Replacement Removal Procedure 1. Remove the control lever. Important: Loosen DO NOT remove the shift lever assembly adjustment nut if replacing the control lever. 2. Remove the control lever boot retainer plastic retainers, if necessary. 3. Remove the control lever boot retainer, if necessary. 4. Remove the control lever boot screws, if necessary. 5. Remove the control lever boot, if necessary. 6. Remove the control lever insulator, if necessary. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Boot, M/T > Component Information > Service and Repair > NV 3500 > Page 7725 1. Install the control lever insulator, if removed. 2. Install the control lever boot to the control lever, if removed. 3. Install the control lever. 4. If alignment of the control lever is necessary, or if the shift lever assembly was replaced perform the following: 1. The nut must be seated at the bottom of the thread runout on the shift lever. 2. Seat the control lever against the shift lever assembly adjustment nut. 3. Back the control lever off the nut in order to align the index mark on the control lever perpendicular to the edge of the control lever boot retainer. 5. Ensure that the index mark is located on the passenger side and that the shift pattern is aligned parallel to the vehicle centerline or rotated no more than 6 degrees clockwise. Notice: Refer to Fastener Notice in Service Precautions. 6. Hold the control lever and tighten the shift lever assembly nut against the control lever. ^ Tighten the nut to 37 Nm (27 ft. lbs.). 7. Seat the control lever boot to the floor. 8. Install the control lever boot screws, if removed. ^ Tighten the screws to 1.6 Nm (14 inch lbs.). 9. Install the control lever boot retainer, if removed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > NV 3500 Transmission Mount: Service and Repair NV 3500 Transmission Mount Replacement Removal Procedure Notice: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission mount to crossmember nut. 3. Remove the transmission mount to transmission bolts. 4. Raise the transmission just enough in order to permit removal of the mount using a suitable transmission jack. 5. Remove the transmission mount. Installation Procedure 1. Position the transmission mount. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the transmission mount to transmission bolts. ^ Tighten the transmission mount bolts to 50 Nm (37 ft. lbs.). 3. Lower the transmission and remove the transmission jack. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > NV 3500 > Page 7730 4. Install the transmission mount to crossmember nut. ^ Tighten the transmission mount to crossmember nut to 40 Nm (30 ft. lbs.). 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > NV 3500 > Page 7731 Transmission Mount: Service and Repair NV 4500 Transmission Mount Replacement Removal Procedure Notice: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission mount to crossmember nut. 3. Remove the transmission mount to transmission bolts. 4. Raise the transmission just enough, in order to permit removal of the mount using a suitable transmission jack. 5. Remove the transmission mount. Installation Procedure 1. Position the transmission mount. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the transmission mount to transmission bolts. ^ Tighten the transmission mount bolts to 50 Nm (37 ft. lbs.). 3. Lower the transmission and remove the transmission jack. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > NV 3500 > Page 7732 4. Install the transmission mount to crossmember nut. ^ Tighten the transmission mount to crossmember nut to 40 Nm (30 ft. lbs.). 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > NV 3500 > Page 7733 Transmission Mount: Service and Repair ZF S6-650 Transmission Mount Replacement Removal Procedure Notice: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission mount to crossmember nuts. 3. Remove the transmission mount bolts to the transmission. 4. Raise the transmission using a suitable transmission jack, just enough in order to permit the removal of the mount. 5. Remove the transmission mount. Installation Procedure 1. Install the rear transmission mount. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the transmission mount bolts. ^ Tighten the transmission mount bolts to 50 Nm (37 ft. lbs.). 3. Lower the transmission. 4. Install the transmission mount to crossmember nuts. ^ Tighten the transmission mount to crossmember nuts to 54 Nm (40 ft. lbs.). 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Locations Power Take-Off: Locations Power Take Off (PTO) Relay Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Locations > Page 7737 C104, C114, C150, C151, C153, C154, And PTO Relay Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions Power Take-Off: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7740 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7741 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7742 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7743 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7744 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7745 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7746 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7747 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7748 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7749 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7750 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7751 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7752 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7753 Power Take-Off: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7754 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7755 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7756 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7757 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7758 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7759 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7760 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7761 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7762 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7763 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7764 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7765 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7766 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7767 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7768 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7769 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7770 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7771 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7772 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7773 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7774 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7775 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7776 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7777 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7778 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7779 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7780 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7781 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7782 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7783 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7784 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7785 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7786 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7787 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7788 Power Take-Off: Connector Views Power Take Off (PTO) Relay Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7789 Power Take Off (PTO) Switch - Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7790 Power Take Off (PTO) Switch - Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Diagram Information and Instructions > Page 7791 Power Take-Off: Electrical Diagrams Power Take-Off (PTO) Diagram Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Page 7792 Power Take-Off: Description and Operation POWER TAKE-OFF (PTO) DESCRIPTION AND OPERATION The PTO is an Upfitter integrated system that allows the user to create an auxiliary power source that will drive either a hydraulic pump or a generator. When the operator requests PTO the PTO switch will be turned ON and the engine RPM will go to a default standby speed. The operator will then press and release the PTO switch to SET and the PTO solenoid will engage. Turning the PTO switch to OFF or pressing the brake pedal will turn the PTO off. The PTO system is integrated with the Cruise Control system and Computers and Control Systems. The PTO system utilizes the following parts: - PTO Switch - Cruise Control Multi-Function Switch - PTO Relay - PTO Solenoid - PCM with 8.1L gasoline only - ECM with 6.6L diesel only - TAC Module with 8.1L gasoline only - TAC Motor with 8.1L gasoline only Voltage will be supplied at all times through the Fog Lamp fuse to the secondary side of the PTO Relay. When the operator turns the ignition switch to RUN, voltage will be supplied through the Cruise fuse to the open PTO switch. When the PTO switch is turned ON voltage will be present through the primary side of the PTO Relay and at the PCM. If the PCM sees all of the requirements for PTO engagement the PCM will send a Class 2 signal to the TAC Module. The TAC Module will use the TAC Motor to increase the engine RPM to the standby speed. When the PTO switch is turned to the SET position and released the PCM will ground the primary side of the PTO Relay. Current will flow through the coil in the PTO Relay and close the normally open contacts. This will allow current to flow to the PTO Solenoid and eventually to ground. In the event that any of the PTO requirements are no longer met then the PCM or TAC will return the engine RPM to idle and turn the PTO Solenoid off. MODES OF OPERATION PTO - Preset Mode (Factory Default Setting) The PTO preset mode is used for stationary applications. PTO will remain engaged while mobile in the preset mode however PTO Preset 1 and PTO Preset 2 speed controls will be inoperative. The engine RPM will also return to normal. This mode provides a default standby speed of 800 or 850 RPM depending on the engine and transmission combination. This mode also provides 2 default PTO control speeds: PTO Preset 1 of 1250 RPM and PTO Preset 2 of 1700 RPM. Please note that the standby speed is not to be used as a PTO control speed. Vehicles not equipped with cruise control will not have the resume speed capability. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Page 7793 PTO Preset Mode Function Chart PTO Preset Mode Function Chart PTO - Variable Mode The PTO speed control mode is used for both stationary and mobile applications. This mode allows PTO to be controlled in a fashion similar to cruise control. The operator is able to hold an engine RPM between 800 and 2200 with the SET switch on the cruise stock or the PTO switch. The operator can "tap up" to increase engine speed in 100 RPM increments with the RESUME switch. The operator may also "tap down" to decrease engine speed with either SET switch on the cruise control multifunction switch or the PTO switch. Vehicles not equipped with cruise control will not have the "tap up" capability. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Page 7794 PTO - Variable Mode Function Chart PTO - Variable Mode Function Chart PTO COMPONENTS PTO Switch The PTO Switch is mounted in the center of the Instrument Panel. The PTO Switch has three positions: OFF, ON and SET. When the PTO switch is in ON voltage will be present on the PTO On Switch Signal circuit at the relay and the PCM. When the switch is held to the SET position, voltage will be present on the PTO Engage Signal circuit at the PCM. The PTO indicator light is integral with the switch and will illuminate when the switch is turned ON. The presence of the indicator being on does not mean that the PTO Solenoid is engaged. The Cruise Control Multi-Function Switch may be used in conjunction with the PTO Switch. Illumination of the switch is provided through the dimming circuit and controlled in part by internal switch logic. Cruise Control Multi-Function Switch The operation of the PTO system may be through the function control switches located on the multifunction turn signal lever. The cruise control function control switches includes the ON/OFF, SET/COAST, and R/A. The switch assembly provides driver control of the PTO as well as the cruise control system. The SET/COAST and R/A switches may be used to increase and decrease engine RPM in increments of 100 RPM. See the chart below for recommended speeds. PTO Relay The PTO Relay is located on the side of the underhood fuse block. The secondary side of the relay is supplied with voltage at all times through the Fog Lamp fuse. The PTO switch controls the voltage to the primary side of the PTO relay while the PCM controls the ground. PTO Solenoid The solenoid is an upfitter supplied part and is replaceable on most PTOs. The PTO solenoid is used on clutch activated PTOs. The PTO relay supplies the solenoid with voltage when the relay is energized. PCM The powertrain control module (PCM) is the control center of the PTO system. Applications with a 6.6L diesel use an ECM. The PCM monitors numerous engine and vehicle functions. To engage the PTO, the PCM must see the following conditions: PTO switch is ON - Engine must be running - Transmission must be in PARK or NEUTRAL - Park Brake must be set for manual transmission only - Vehicle speed must be zero in Preset Mode only - Brake or Clutch must not be depressed The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance. The PCM also performs a diagnostic test on the Electronic Throttle Control system. TAC Module The TAC module is the control center for the electronic throttle system. The TAC module and the PCM communicate through a dedicated redundant serial data circuit. The TAC module and the PCM monitor the commanded throttle position and compare the commanded position to the actual throttle position. This is accomplished by monitoring the APP and the throttle position (TP) sensor. These 2 values must be within a calibrated value of each other or a DTC may be set. The TAC module also monitors each individual circuit of the TP sensor and the APP to verify proper operation. The TAC Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams > Page 7795 module commands the TAC motor to increase or decrease the engine RPM. TAC Motor The TAC motor is part of the throttle body and controls the positions of the throttle. The motor is bi-directional and is controlled by the TAC module. The TAC motor increases or decreases the engine RPM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Power Take-Off: Initial Inspection and Diagnostic Overview Diagnostic Starting Point DIAGNOSTIC STARTING POINT - POWER TAKE-OFF (PTO) IMPORTANT: The following steps must be completed before using the symptom tables. 1. Perform the Power Take-Off (PTO) Diagnostic System Check emphasis before using the Symptom Tables in order to verify that all of the following are true: Refer to Diagnostic System Check - Power Take-Off (PTO). - There are no DTCs set. - The control module(s) can communicate via the serial data link. See: Diagnostic System Check 2. Review the system Description and Operation in order to familiarize yourself with the system functions. Refer to emphasis Power Take-Off (PTO) Description and Operation. Visual/Physical Inspection Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. - Inspect the transmission for the proper transmission fluid level. - Inspect the hydraulic reservoir for the proper hydraulic fluid level. - Inspect the upfitter connections at the transmission. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Power Take-Off Does Not Engage emphasis - Engine RPM Does Not Increase With Power Take-Off Engaged emphasis - Power Take-Off Indicator Inoperative emphasis Diagnostic System Check DIAGNOSTIC SYSTEM CHECK - POWER TAKE-OFF (PTO) TEST DESCRIPTION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7798 Steps 1-4 Steps 5-6 The number(s) below refer to the step number(s) on the diagnostic table. 2. Lack of communication may be due to a partial or total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 3. The presence of DTCs indicates that the PCM or TAC has detected a fault. 4. The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. 5. This step insures that the PTO options in the scan tool are set according to the upfitters recommendations. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7799 Power Take-Off: Symptom Related Diagnostic Procedures - Symptoms - Power Take-Off (PTO) SYMPTOMS - POWER TAKE-OFF (PTO) IMPORTANT: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Power Take-Off (PTO) before using the Symptom Tables in order to verify that all of the following are true: There are no PCM or TAC module DTCs set. - The PCM and TAC module can communicate to each other via the serial data links. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Power Take-Off (PTO) Description and Operation. VISUAL/PHYSICAL INSPECTION - Inspect the upfitter connections of the PTO system. - Inspect the easily accessible, or the visible system components for obvious damage or conditions which could cause the symptom. - Inspect the transmission and the hydraulic pump for the proper fluid level. INTERMITTENT Faulty electrical connections or wiring may be the cause of intermittent conditions. SYMPTOM LIST Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: - Power Take-Off (PTO) Does Not Engage - Engine RPM Does Not Increase with Power Take-Off Engaged - Power Take-Off (PTO) Indicator Inoperative Engine RPM Does Not Increase With Power Take-Off Engaged ENGINE RPM DOES NOT INCREASE WITH POWER TAKE-OFF ENGAGED CIRCUIT DESCRIPTION When the Power Take-Off (PTO) switch is turned to the ON position and all PTO engage conditions are met, the engine RPM should increase to the standby speed. When the Powertrain Control Module (PCM) receives the signal from the PTO switch the PCM will send a signal to the Throttle Actuator Control Module (TAC). The TAC module controls the TAC motor which changes the position of the throttle. Communications between the two modules is monitored and checked for accuracy by the PCM. DTCs may be recorded in the event of the failure. The 6.6L diesel engine does not have a TAC system and the engine RPM is strictly controlled by the ECM and the Fuel Injection Control Module. TEST DESCRIPTION Steps 1-2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7800 Steps 3-9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7801 Steps 10-13 The numbers below refer to the step numbers on the diagnostic table. 3. This step checks for other system DTCs that may affect the PTO. 6. This step tests the PCM for the PTO Enable signal. 7. This step tests the communication between the PCM and the TAC module. 8. This step tests the PTO On Switch Signal circuit. 9. This step tests the PTO On Switch-Signal circuit for an open, high resistance or short to ground. 10. This step tests the Serial Data circuits for an open, high resistance or short to ground. Power Take-Off (PTO) Does Not Engage POWER TAKE-OFF (PTO) DOES NOT ENGAGE CIRCUIT DESCRIPTION This symptom table aids in the diagnosis of a failed power take-off (PTO) solenoid engagement. This diagnostic does not expose a mechanical condition with the PTO itself. Voltage is supplied at all times through the cruise fuse to the secondary side of the relay. When the relay is energized, the contacts close and current is allowed to flow to the PTO solenoid. The solenoid has its own external ground. When the ignition switch is in the RUN position, voltage is present at the PTO switch. When the PTO switch is in the ON position, voltage is present at the coil of the relay and at the PCM. If the PCM sees all of the conditions necessary to engage the solenoid, the PCM grounds the primary circuit of the relay. TEST DESCRIPTION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7802 Steps 1-3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7803 Steps 4-10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7804 Steps 11-18 Step 19 The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for an open fog lamp fuse. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7805 3. This step tests for open cruise fuse. 4. This step tests the battery positive circuit for battery voltage. 5. This step tests the battery positive circuit for an open. 6. This step tests the PTO relay output circuit for an open. 7. This step tests the PTO ON signal circuit for battery voltage. 8. This step tests the PTO ON signal circuit for an open. 9. This step tests the cruise control set/coast switch signal circuit for battery voltage. 10. This step tests the PTO status circuit for an open. 11. This step tests the PTO switch and PTO unit ground circuits for an open. 12. This step tests the battery positive and PTO relay output circuits for a short to ground. 13. This step tests the ignition 3 circuit for a short to ground. 14. This step tests the cruise control ON switch signal, cruise control set/coast signal, PTO status, and PTO ON signal circuits for a short to ground. 15. This step tests the control side of the PTO relay for proper operation. Power Take-Off (PTO) Indicator Inoperative POWER TAKE-OFF (PTO) INDICATOR INOPERATIVE CIRCUIT DESCRIPTION This symptom chart will aid in diagnosing a failed Power Take-Off (PTO) indicator. This diagnostic assumes that the PTO solenoid is functional and only the indicator is failing to come on. When the ignition switch is in RUN, voltage should be present on the Ignition 3 Voltage circuit. When the PTO switch is turned to ON, the LED will illuminate. The indicator has its own ground circuit. The LED and PTO solenoid have different ground circuits. Therefore, the LED may be illuminated when the PTO solenoid is disengaged. TEST DESCRIPTION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7806 Steps 1-6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7807 Steps 7-8 The number below refers to the step number on the diagnostic table. 5. This step tests the ground circuit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Testing and Inspection > Page 7808 Power Take-Off: Service and Repair POWER TAKE-OFF (PTO) SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the I/P cluster bezel. 2. Pull out the switch housing from the I/P. 3. Disconnect the wire connector to the PTO switch. 4. Remove the PTO switch from the switch housing. INSTALLATION PROCEDURE 1. Install the PTO switch to the housing 2. Connect the wire connector to the switch. 3. Install the switch housing to the I/P till it clicks into place. 4. Install the I/P cluster bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Transmission Control Module Replacement Control Module: Service and Repair Transmission Control Module Replacement Transmission Control Module (TCM) Replacement Removal Procedure Important: ^ Remove any debris from the transmission control module(TCM) connector surfaces before servicing the TCM. Inspect the TCM module connector gaskets when diagnosing or replacing the TCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the TCM. ^ The ignition must be OFF when disconnecting or reconnecting power to the TCM. 1. Disconnect the negative battery cable. 2. Remove the TCM cover bolts (1) located on the left side of the radiator shroud. 3. Pull the cover and TCM up and away from the radiator shroud. 4. Push up on the retainers (1) in order to remove the TCM from the cover. 5. Disconnect the TCM electrical connectors (2) and remove the TCM from the vehicle. Installation Procedure 1. Connect the TCM electrical connectors (2) to the TCM. 2. Install the TCM to the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Transmission Control Module Replacement > Page 7815 3. Using the alignment tabs (1), install the cover and module to the radiator shroud. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the TCM cover bolts (1) to the radiator shroud. ^ Tighten the bolts to 9 Nm (80 inch lbs.). 5. Connect the negative battery cable. 6. Reprogram the TCM. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Transmission Control Module Replacement > Page 7816 Control Module: Service and Repair Transmission Control Module Reprogramming Procedures Transmission Control Module Reprogramming Procedures Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install new module before proceeding. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the Electronic Control Unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to Program/Reprogram. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Reconnect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the Electronic Control Unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to Program/Reprogram. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 02-04-21-006E > Jul > 06 > AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: Customer Interest AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 02-04-21-006E > Jul > 06 > AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 > Page 7826 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 02-04-21-006E > Jul > 06 > AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: All Technical Service Bulletins AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 02-04-21-006E > Jul > 06 > AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 > Page 7832 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 05-04-21-002 > Mar > 05 > Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 05-04-21-002 > Mar > 05 > Drivetrain - Transfer Case Control Module Replacement > Page 7837 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 05-04-21-002 > Mar > 05 > Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 05-04-21-002 > Mar > 05 > Drivetrain - Transfer Case Control Module Replacement > Page 7843 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > NVG 246-NP8 Control Module: Locations NVG 246-NP8 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > NVG 246-NP8 > Page 7846 Control Module: Locations NVG 263-NP1 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 7847 Control Module: Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 7848 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 7849 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 Control Module: Service and Repair NVG 246-NP8 Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install new module before proceeding. Before reprogramming close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to do so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Disconnect the scan tool from the vehicle and connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to Program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Reconnect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 7852 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 7853 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 7854 Control Module: Service and Repair NVG 263-NP1 Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 7855 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install a new module before proceeding. Before reprogramming, close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to do so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 7856 Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information about the type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Connect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information about the type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions Brake Switch - TCC: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7863 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7864 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7865 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7866 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7867 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7868 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7869 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7870 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7871 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7872 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7873 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7874 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7875 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7876 Brake Switch - TCC: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7877 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7878 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7879 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7880 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7881 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7882 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7883 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7884 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7885 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7886 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7887 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7888 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7889 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7890 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7891 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7892 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7893 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7894 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7895 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7896 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7897 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7898 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7899 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7900 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7901 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7902 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7903 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7904 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7905 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7906 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7907 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7908 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7909 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7910 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 7911 Power, Ground and Brake Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Component Locations Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Component Locations > Page 7916 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 7917 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 7918 Fluid Pressure Sensor/Switch: Service and Repair Pressure Switch Manifold Replacement Removal Procedure 1. Important: Individual pressure switches cannot be replaced. When any pressure switch needs replacing, the entire assembly must be replaced. Important: The G solenoid has been removed for clarity. Remove the oil pan and suction filter. 2. Remove the two bolts (2). Remove the reverse signal tube (1). 3. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the internal wiring harness connector from the pressure switch assembly (2). 4. Remove five bolts (1). Remove the pressure switch assembly (2). Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 7919 1. Notice: Refer to Fastener Notice in Service Precautions. Place the new pressure switch manifold assembly (2) in position and install one bolt (1) in a recessed location to hold it into position. Start the remaining four bolts (1) in recessed locations and tighten the bolts by hand. Torque the bolts to 12 Nm (108 inch lbs.). 2. Connect the internal wiring harness connector to the pressure switch assembly. 3. Install the reverse signal tube (1). Install two bolts (2). ^ Tighten the bolts to 12 Nm (108 inch lbs.). 4. Install the oil pan and suction filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch: Testing and Inspection 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 7924 Steps 1-9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 7925 Tow/Haul Switch: Testing and Inspection 4L80-E/4L85-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between up shifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit checks are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 7926 Steps 1-9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start Transmission Position Switch/Sensor: Customer Interest A/T - Slow/No Gear Engagement/Engine No Start Bulletin No.: 02-07-30-011C Date: June 21, 2004 TECHNICAL Subject: Slow or No Engagement of Automatic Transmission, No Start, Blank PRNDL Display, Flashing PRNDL, DTC P0708, P0872, P0847, P0875, P1711, P1713 or U1000 Set (Diagnose Condition, Repair According to Procedure) Models: 2001-2004 Chevrolet Silverado 2001-2004 GMC Sierra with Allison(R) LCT1000 Automatic Transmission (RPO M74) and 6.6L Duramax(TM) Diesel Engine (RPO LB7) or 8.1L Gas Engine (RPO L18) Supercede: This bulletin is being revised to add model years and additional model information and add graphics. Please discard Corporate Bulletin Number 02-07-30-011B (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions. ^ The PRNDL display is flashing. ^ The engine will not start. ^ The "Service Engine Soon" Indicator lamp is illuminated. ^ The transmission does not shift properly. ^ The vehicle will not move, transmission will not engage. Cause Moisture contamination within the Park Neutral Position (PNP) Switch may cause this condition. This is sometimes referred to as the Neutral Start Back-up (NSBU) Switch. On a left turn, water spray from the left front tire is directed directly at this switch. Proper installation of the "Front Shield" and "Rear Shield" are essential for proper repairs. Technician Diagnosis This bulletin ONLY applies to vehicles equipped with a two connector PNP switch as shown above. A complete and through diagnosis must be performed by a qualified electrical technician to determine the cause and avoid needless replacement of good components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 7935 Important: The Transmission Control Module (TCM) and or the Pressure Switch Manifold (PSM) should NOT be replaced unless properly diagnosed. They are probably not the cause of the concern. It is often assumed the module is the cause of the concern when, in fact, it is another component or the wiring between the components that causes the concern. Important: Remember, everything starts with a properly operating Neutral Start Back Up (NSBU) switch. The NSBU switch has been incorporated into what is now called the Park Neutral Position (PNP) switch. If the PNP switch does not provide the proper voltage signal to the module indicating the transmission is in either Park or Neutral, the module will not allow the starter operation. After the engine is started, and the shift lever is moved to either Reverse or one of the drive positions, the range selected portion of the PNP switch portion provides a voltage input to the module as to what range the driver has manually selected for transmission operation. The module then controls pressures, shift points and other transmission functions based on the voltage input received from the range portion of the PNP switch. The technician may find one or more of the following conditions. The list of these conditions does not imply any type of frequency or order. They are random events and may occur in any order. ^ DTC P0708, Neutral start/backup (PNP or NSBU) switch ^ DTC P0847, Pressure Switch Manifold (PSM) ^ DTC P0872, Pressure Switch Manifold (PSM) ^ DTC P0875, Pressure Switch Manifold (PSM) ^ DTC P1711, Pressure Switch Manifold (PSM) ^ DTC P1713, Pressure Switch Manifold (PSM) ^ DTC U1000, Serial Data Communications ^ Blank PRNDL Display ^ Flashing PRNDL Display ^ Slow or No Engagement of Automatic Transmission Blank PRNDL Display A blank PRNDL display may indicate a condition with the PNP switch and/or one or more of the four signal circuits from the PNP to the TCM. 1. Pin A, Circuit 771 (BLK/WHT) 2. Pin B, Circuit 773 (GRA) 3. Pin C, Circuit 776 (WHT) 4. Pin D, Circuit 772 (YEL) Or, a blank PRNDL display may also occur if an out of line condition exists with the Serial Data Circuit (CKT 2470, yellow wire) from the TCM to Splice Pack 205. Diagnostic Tip 1. Connect the Tech 2(R) to the vehicle. 2. Power up the Tech 2(R). 3. Does the Tech 2(R) communicate with the TCM? If not, inspect the serial data circuit, CKT 2470 (Yellow wire), between the TCM and Splice Pack 205. Specifically inspect connector C106, a five terminal connector located below the left side underhood bussed electrical center, directly beneath the red battery cable terminal connection. Perform a mating terminal pull test on all of the terminals in this connector. Repair as required. 4. Observe the Gear Selected screen on the scan tool. The following values should be shown on the Tech 2(R) display and the vehicle's instrument panel cluster (if equipped with the I/P display). ^ "8" (shifter should be in the Park position) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 7936 ^ "7" (shifter should be in the Reverse position) ^ "5" (shifter should be in the Drive position) ^ "3" (shifter should be in the Third gear position) ^ "2" (shifter should be in the Second gear position) ^ "1" (shifter should be in the First gear position) ^ "0" (shifter should be in the Neutral Position) If the Gear Selected display does not match the shifter position in the vehicle, diagnose using one of the following methods. ^ Obtain a new PNP switch kit, P/N 29540479, from the Parts Department. ^ 0.1. Disconnect the wiring connector from the original transmission mounted PNP switch. ^ 0.2. Connect the new switch to the wiring connector. ^ 0.3. Return to Step # 4 above and observe the display as you rotate the switch. If all positions indicate properly, refer to the Correction section below. ^ Use the DTC P0708 diagnostic chart in Service Information (SI) under Transmission/Transaxle/Automatic Transmission - Allison. Reference SI Document ID # 769549 for the wiring schematic for this symptom. The PNP switch, as referenced in SI, is known as the NSBU switch in the Parts information. It is now serviced with a Park Neutral Position Switch Kit, P/N 29540479. Flashing PRNDL Display A flashing PRNDL display may be the result of incorrect sensor inputs or transmission abuse protection modes being received by the TCM. The following are some of these conditions: ^ The transfer case is/was in Neutral. ^ The transfer case is/was shifted into Neutral when the vehicle is moving. ^ A decrease of the input turbine speed was not detected when the gear selector was moved into any gear. ^ A low transmission fluid level. ^ A misadjusted PNP/NSBU switch. ^ Turbine input speed or output speed sensor failure. ^ Failures of the shift solenoids to route the transmission oil to the proper clutch assemblies within the transmission. ^ Failures of the transmission clutch packs (C1 or C5 for first gear, C3 or C5 for Reverse). ^ Failure to detect proper line pressures when a gear range is selected, which may be the result of normal maintenance such as a transmission fluid change having been completed, or the transmission pan was removed for a filter replacement or other type service. Transmission abuse protection modes are encountered when a customer performs one of the following types of maneuvers: ^ Shifting from Neutral to Drive/Reverse when the engine RPM is greater than 1400 RPM. ^ Shifting from Drive to Reverse when the throttle position (TPS) is greater than 25%, such as rocking the vehicle when stuck in an attempt to free the vehicle. ^ When the transmission output speed is greater than 300 RPM from attempted changes in direction such as Reverse to Drive, Drive to Reverse or Neutral to Reverse shifts. When the TCM encounters any one of the above conditions, the TCM will flash the PRNDL and default the transmission to Neutral. A flashing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 7937 PRNDL indicates something is/was incorrect. The transmission may need the attention of a qualified service technician. Correction 1. Disconnect the wiring harness from the PNP switch. 2. Disconnect the shift linkage/cable from the shift lever at the transmission. 3. With a wrench keeping the shift lever from rotating, remove the nut from the end of the selector shaft. 4. Use a file to remove any burrs or raised metal where the selector lever was seated against the shoulder of the selector shaft. Important: If the old PNP switch will not slide from the selector shaft without the effort, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 5. Remove the two bolts that attach the PNP switch and remove the switch by sliding it outward over the selector shaft. 6. Make sure the selector shaft is in the N (neutral) position (using a wrench on the selector shaft flats, rotate the shaft to its furthest clockwise position and then rotate counterclockwise two detents). Important: If the new PNP switch will not slide onto the selector shaft easily, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 7. Slide the new PNP switch over the selector shaft with the neutral assurance bracket 920 facing outward and maintaining the correct PNP switch orientation to the selector shaft. Install and hand tighten the two PNP switch attaching bolts so that the PNP switch and bracket may be rotated within the adjusting slots with some effort. 8. While holding the neutral assurance bracket in engagement with the PNP switch, tighten the two bolts that attach the PNP switch to the transmission case. Tighten Tighten the bolts to 27 N.m (20 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 7938 9. Remove and discard the neutral assurance bracket. Important: Installation of the front shield and rear shields are important. Without proper installation of the shield, a return repair is probable. Follow all directions as listed on the installation instructions sheet included in the Switch kit, P/N 29540479. 10. Fit the new shield onto the PNP switch so that it fits securely against the switch. Make sure this is done before reinstalling the shift lever. 11. Reinstall the shift lever. With a wrench keeping the shift lever from rotating, install the nut on the end of the selector shaft. Tighten. Tighten the nut to 24 N.m (18 lb ft). 12. Connect the wiring harness connectors to the PNP switch. 13. Attach the selector cable to the lever. Check and adjust if needed. 14. Go back to step 4 of the Diagnostics and insure the Tech 2 readings match the shift lever positions. Important: Clear all DTCs before returning the vehicle to the customer. 15. Return the vehicle to the customer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 7939 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T Slow/No Gear Engagement/Engine No Start Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Slow/No Gear Engagement/Engine No Start Bulletin No.: 02-07-30-011C Date: June 21, 2004 TECHNICAL Subject: Slow or No Engagement of Automatic Transmission, No Start, Blank PRNDL Display, Flashing PRNDL, DTC P0708, P0872, P0847, P0875, P1711, P1713 or U1000 Set (Diagnose Condition, Repair According to Procedure) Models: 2001-2004 Chevrolet Silverado 2001-2004 GMC Sierra with Allison(R) LCT1000 Automatic Transmission (RPO M74) and 6.6L Duramax(TM) Diesel Engine (RPO LB7) or 8.1L Gas Engine (RPO L18) Supercede: This bulletin is being revised to add model years and additional model information and add graphics. Please discard Corporate Bulletin Number 02-07-30-011B (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions. ^ The PRNDL display is flashing. ^ The engine will not start. ^ The "Service Engine Soon" Indicator lamp is illuminated. ^ The transmission does not shift properly. ^ The vehicle will not move, transmission will not engage. Cause Moisture contamination within the Park Neutral Position (PNP) Switch may cause this condition. This is sometimes referred to as the Neutral Start Back-up (NSBU) Switch. On a left turn, water spray from the left front tire is directed directly at this switch. Proper installation of the "Front Shield" and "Rear Shield" are essential for proper repairs. Technician Diagnosis This bulletin ONLY applies to vehicles equipped with a two connector PNP switch as shown above. A complete and through diagnosis must be performed by a qualified electrical technician to determine the cause and avoid needless replacement of good components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T Slow/No Gear Engagement/Engine No Start > Page 7945 Important: The Transmission Control Module (TCM) and or the Pressure Switch Manifold (PSM) should NOT be replaced unless properly diagnosed. They are probably not the cause of the concern. It is often assumed the module is the cause of the concern when, in fact, it is another component or the wiring between the components that causes the concern. Important: Remember, everything starts with a properly operating Neutral Start Back Up (NSBU) switch. The NSBU switch has been incorporated into what is now called the Park Neutral Position (PNP) switch. If the PNP switch does not provide the proper voltage signal to the module indicating the transmission is in either Park or Neutral, the module will not allow the starter operation. After the engine is started, and the shift lever is moved to either Reverse or one of the drive positions, the range selected portion of the PNP switch portion provides a voltage input to the module as to what range the driver has manually selected for transmission operation. The module then controls pressures, shift points and other transmission functions based on the voltage input received from the range portion of the PNP switch. The technician may find one or more of the following conditions. The list of these conditions does not imply any type of frequency or order. They are random events and may occur in any order. ^ DTC P0708, Neutral start/backup (PNP or NSBU) switch ^ DTC P0847, Pressure Switch Manifold (PSM) ^ DTC P0872, Pressure Switch Manifold (PSM) ^ DTC P0875, Pressure Switch Manifold (PSM) ^ DTC P1711, Pressure Switch Manifold (PSM) ^ DTC P1713, Pressure Switch Manifold (PSM) ^ DTC U1000, Serial Data Communications ^ Blank PRNDL Display ^ Flashing PRNDL Display ^ Slow or No Engagement of Automatic Transmission Blank PRNDL Display A blank PRNDL display may indicate a condition with the PNP switch and/or one or more of the four signal circuits from the PNP to the TCM. 1. Pin A, Circuit 771 (BLK/WHT) 2. Pin B, Circuit 773 (GRA) 3. Pin C, Circuit 776 (WHT) 4. Pin D, Circuit 772 (YEL) Or, a blank PRNDL display may also occur if an out of line condition exists with the Serial Data Circuit (CKT 2470, yellow wire) from the TCM to Splice Pack 205. Diagnostic Tip 1. Connect the Tech 2(R) to the vehicle. 2. Power up the Tech 2(R). 3. Does the Tech 2(R) communicate with the TCM? If not, inspect the serial data circuit, CKT 2470 (Yellow wire), between the TCM and Splice Pack 205. Specifically inspect connector C106, a five terminal connector located below the left side underhood bussed electrical center, directly beneath the red battery cable terminal connection. Perform a mating terminal pull test on all of the terminals in this connector. Repair as required. 4. Observe the Gear Selected screen on the scan tool. The following values should be shown on the Tech 2(R) display and the vehicle's instrument panel cluster (if equipped with the I/P display). ^ "8" (shifter should be in the Park position) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T Slow/No Gear Engagement/Engine No Start > Page 7946 ^ "7" (shifter should be in the Reverse position) ^ "5" (shifter should be in the Drive position) ^ "3" (shifter should be in the Third gear position) ^ "2" (shifter should be in the Second gear position) ^ "1" (shifter should be in the First gear position) ^ "0" (shifter should be in the Neutral Position) If the Gear Selected display does not match the shifter position in the vehicle, diagnose using one of the following methods. ^ Obtain a new PNP switch kit, P/N 29540479, from the Parts Department. ^ 0.1. Disconnect the wiring connector from the original transmission mounted PNP switch. ^ 0.2. Connect the new switch to the wiring connector. ^ 0.3. Return to Step # 4 above and observe the display as you rotate the switch. If all positions indicate properly, refer to the Correction section below. ^ Use the DTC P0708 diagnostic chart in Service Information (SI) under Transmission/Transaxle/Automatic Transmission - Allison. Reference SI Document ID # 769549 for the wiring schematic for this symptom. The PNP switch, as referenced in SI, is known as the NSBU switch in the Parts information. It is now serviced with a Park Neutral Position Switch Kit, P/N 29540479. Flashing PRNDL Display A flashing PRNDL display may be the result of incorrect sensor inputs or transmission abuse protection modes being received by the TCM. The following are some of these conditions: ^ The transfer case is/was in Neutral. ^ The transfer case is/was shifted into Neutral when the vehicle is moving. ^ A decrease of the input turbine speed was not detected when the gear selector was moved into any gear. ^ A low transmission fluid level. ^ A misadjusted PNP/NSBU switch. ^ Turbine input speed or output speed sensor failure. ^ Failures of the shift solenoids to route the transmission oil to the proper clutch assemblies within the transmission. ^ Failures of the transmission clutch packs (C1 or C5 for first gear, C3 or C5 for Reverse). ^ Failure to detect proper line pressures when a gear range is selected, which may be the result of normal maintenance such as a transmission fluid change having been completed, or the transmission pan was removed for a filter replacement or other type service. Transmission abuse protection modes are encountered when a customer performs one of the following types of maneuvers: ^ Shifting from Neutral to Drive/Reverse when the engine RPM is greater than 1400 RPM. ^ Shifting from Drive to Reverse when the throttle position (TPS) is greater than 25%, such as rocking the vehicle when stuck in an attempt to free the vehicle. ^ When the transmission output speed is greater than 300 RPM from attempted changes in direction such as Reverse to Drive, Drive to Reverse or Neutral to Reverse shifts. When the TCM encounters any one of the above conditions, the TCM will flash the PRNDL and default the transmission to Neutral. A flashing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T Slow/No Gear Engagement/Engine No Start > Page 7947 PRNDL indicates something is/was incorrect. The transmission may need the attention of a qualified service technician. Correction 1. Disconnect the wiring harness from the PNP switch. 2. Disconnect the shift linkage/cable from the shift lever at the transmission. 3. With a wrench keeping the shift lever from rotating, remove the nut from the end of the selector shaft. 4. Use a file to remove any burrs or raised metal where the selector lever was seated against the shoulder of the selector shaft. Important: If the old PNP switch will not slide from the selector shaft without the effort, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 5. Remove the two bolts that attach the PNP switch and remove the switch by sliding it outward over the selector shaft. 6. Make sure the selector shaft is in the N (neutral) position (using a wrench on the selector shaft flats, rotate the shaft to its furthest clockwise position and then rotate counterclockwise two detents). Important: If the new PNP switch will not slide onto the selector shaft easily, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 7. Slide the new PNP switch over the selector shaft with the neutral assurance bracket 920 facing outward and maintaining the correct PNP switch orientation to the selector shaft. Install and hand tighten the two PNP switch attaching bolts so that the PNP switch and bracket may be rotated within the adjusting slots with some effort. 8. While holding the neutral assurance bracket in engagement with the PNP switch, tighten the two bolts that attach the PNP switch to the transmission case. Tighten Tighten the bolts to 27 N.m (20 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T Slow/No Gear Engagement/Engine No Start > Page 7948 9. Remove and discard the neutral assurance bracket. Important: Installation of the front shield and rear shields are important. Without proper installation of the shield, a return repair is probable. Follow all directions as listed on the installation instructions sheet included in the Switch kit, P/N 29540479. 10. Fit the new shield onto the PNP switch so that it fits securely against the switch. Make sure this is done before reinstalling the shift lever. 11. Reinstall the shift lever. With a wrench keeping the shift lever from rotating, install the nut on the end of the selector shaft. Tighten. Tighten the nut to 24 N.m (18 lb ft). 12. Connect the wiring harness connectors to the PNP switch. 13. Attach the selector cable to the lever. Check and adjust if needed. 14. Go back to step 4 of the Diagnostics and insure the Tech 2 readings match the shift lever positions. Important: Clear all DTCs before returning the vehicle to the customer. 15. Return the vehicle to the customer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 02-07-30-011C > Jun > 04 > A/T Slow/No Gear Engagement/Engine No Start > Page 7949 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 7950 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 7951 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 7954 Transmission Position Switch/Sensor: Adjustments Automatic Transmission - Allison Park/Neutral Position Switch Adjustment ^ Tools Required J 41364-A PNP Switch Adjusting Tool Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Make sure the selector shaft is in the N (Neutral) position as follows: ^ Place a wrench on the selector shaft flats and rotate the shaft to its furthest clockwise position. ^ Rotate the selector shaft counter-clockwise two detents. 2. Be sure that J 41364-A (2) is in the proper position on PNP switch (1). 3. While maintaining the correct PNP switch-to-selector-shaft alignment, slide the new PNP switch (5) over the selector shaft (4). 4. Notice: Refer to Component Fastener Tightening Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 7955 While holding J 41364-A in engagement with the PNP switch, install the two bolts (6) so that the PNP switch may be rotated with some effort. ^ Tighten the two bolts (6) to 27 Nm (20 ft. lbs.). 5. Remove J 41364-A. 6. Install splash shield (1), concave side toward PNP switch (3), over selector shaft (2). 7. Notice: Refer to Transmission Selector Shaft Abuse Notice in Service Precautions. Reinstall Shift Lever (2). Install nut (3), by hand, on the end of selector shaft (4). Use a wrench (1) to keep the shift lever from rotating. ^ Tighten nut (3) to 24 Nm (18 ft. lbs.) 8. Reconnect the shift selector linkage/cable to the shift lever (2). 9. Connect the external wiring harness to the PNP switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L80-E/4L85-E Park/Neutral Position Switch Replacement Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7958 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7959 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7960 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Park Lock Pawl and Actuator Replacement Park Lock Pawl and Actuator Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the park/neutral position (PNP) switch. 3. Remove the manual shaft nut and pin. 4. Remove the detent lever and actuator. 5. Remove the parking pawl bracket bolts. 6. Remove the parking pawl return spring. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7961 7. Use the modified screw extractor in order to remove the plug. 8. Remove the parking pawl shaft retainer, shaft and pawl. 9. Important: If the manual shaft binds in the case during removal, file or sand the shaft in the area adjacent to the detent lever. Remove the manual shaft. 10. Remove the manual shaft seal. Installation Procedure 1. Install the pawl shaft. 2. Install the parking pawl. 3. Install the plug using a 8 mm or (5/16 inch) rod with Loctite® or equivalent. 4. Install the retainer. 5. Install the pawl return spring. 6. Install the detent lever to the actuator. 7. Install the actuator over the parking pawl. 8. Install the manual shaft seal. 9. Lubricate the manual shaft with transmission oil and install the manual shaft into the case. 10. Install the nut on the shaft. 11. Install the roll pin. 12. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7962 Install the parking lock bracket bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 13. Install the PNP switch. 14. Install the transmission filter. 15. Fill the transmission to the proper level with Dexron® III transmission fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7963 Transmission Position Switch/Sensor: Service and Repair Automatic Transmission - Allison Park/Neutral Position Switch Replacement PNP Switch Removal Refer to Park/Neutral Position Switch Removal. PNP Switch Install Refer to Park/Neutral Position Switch Installation. 7. Notice: Refer to Transmission Selector Shaft Abuse Notice in Service Precautions. Reinstall shift lever (2). Install nut (3), by hand, on the end of selector shaft (4). Use a wrench (1) to keep the shift lever from rotating. ^ Tighten nut (3) to 24 Nm (18 ft. lbs.). 8. Reconnect the shift selector linkage/cable to the shift lever (2). 9. Connect the external wiring harness to the PNP switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Electrical Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Electrical Specifications > Page 7968 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 7969 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E Transmission Speed Sensor: Diagrams Automatic Transmission - 4L80-E/4L85-E Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 7972 Transmission Speed Sensor: Diagrams Automatic Transmission - Allison Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 7973 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E Transmission Speed Sensor: Service and Repair Automatic Transmission - 4L80-E/4L85-E Input Shaft Speed Sensor Replacement Input Shaft Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1). 5. Inspect the input speed sensor (1) for any evidence of damage. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7976 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the input speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector (1). 5. Lower the vehicle. Output Shaft Speed Sensor Replacement Output Shaft Speed Sensor Replacement Removal Procedure Important: This procedure is for 2-wheel drive (2WD) vehicles only. If the vehicle is equipped with 4-wheel drive (4WD), the output speed sensor is located on the transfer case. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7977 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2). 5. Inspect the output speed sensor (2) for any evidence of damage. Installation Procedure 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the output speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7978 4. Connect the output speed sensor (2) electrical connector. 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7979 Transmission Speed Sensor: Service and Repair Automatic Transmission - Allison Speed Sensor Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Be sure the vehicle ignition is turned off. 2. Disconnect the external wiring harness from the speed sensor. 3. Remove the bolt (1) from the speed sensor and carefully remove the speed sensor (2). Installation Procedure 1. Important: Do not rotate the sensor in its retaining bracket. Changing the sensor/bracket orientation may cause improper operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 7980 Install a new a O-ring (3) on the speed sensor (2). Lubricate the O-ring with clean transmission fluid. 2. Install the new speed sensor (2) into the speed sensor bore. Align the hole in the retaining bracket with the bolt hole in the speed sensor boss. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor bolt (1). ^ Tighten bolt (1) to 12 Nm (108 inch lbs.). 4. Reconnect the external wiring harness to the speed sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Electrical Specifications Transmission Temperature Sensor/Switch: Electrical Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Electrical Specifications > Page 7985 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Electrical Specifications > Page 7986 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Component Locations Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Component Locations > Page 7989 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Instrument Panel Switches-LH Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 7994 Four Wheel Drive Selector Switch: Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 7995 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Transfer Case - NVG 246-NP8 Four Wheel Drive Selector Switch: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (I/P) cluster bezel. 2. Using a flat-tipped screwdriver, gently pry the retaining clips open on the housing. 3. Slide out the selector switch until the electrical connector are accessible. 4. Disconnect the selector switch electrical connectors (2, 3). 5. Remove the selector switch from the housing. Installation Procedure 1. Position the selector switch close to the housing so the electrical connectors can be connected. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Transfer Case - NVG 246-NP8 > Page 7998 2. Connect the selector switch electrical connectors (2, 3). 3. Slide the selector switch into the housing until the switch snaps into place. Important: Make sure that the selector switch is seated properly in the housing before installing the I/P cluster bezel. 4. Install the I/P cluster bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Transfer Case - NVG 246-NP8 > Page 7999 Four Wheel Drive Selector Switch: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (IP) cluster bezel. 2. Pull the tabs on the side of the transfer case driver control switch out. 3. Pull the transfer case driver control switch straight out from the panel. Installation Procedure 1. Important: Make sure that the transfer case control switch is seated properly in the instrument panel before installing the instrument panel trim bezel. Install the transfer case driver control switch into the instrument panel. 2. Install the IP cluster bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair Gear Sensor/Switch: Service and Repair Encoder Motor Sensor Replacement Removal Procedure Important: For ease of reassembly, shift the transfer case to 2HI prior to removing any components. 1. Remove the encoder motor. 2. Place the encoder motor on a clean work bench, 3. Remove the 2 screws (2) from the motor cover. 4. Remove the 2 screws (1) from the casting. 5. Remove the cover. 6. Remove and save the shim on the output gear. 7. Remove and discard the orange rubber seal from the cover. 8. Remove the output gear (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Page 8003 9. Disassemble the harness connector (1) from the encoder. 10. Remove the encoder from the output shaft using a flat tip screwdriver. Installation Procedure 1. Assemble the harness to the NEW encoder with the connector legend "TOP" (1) and the encoder part number facing up. 2. Assemble the output shaft into the encoder, being sure to align the encoder tab with the groove on the shaft. 3. Ensure the encoder is seating properly on the output gear. 4. Place the output shaft encoder on the casting. 5. Place the grommet harness on the casting slot, the flat area on the grommet will be facing up. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Page 8004 6. With the output gear encoder assembly in hand, carefully align the casting and output gear timing marks (1). 7. At the same time, be sure to align the encoder phasing post (1) with the phasing slot (2) in the casting and insert the shaft into the bushing. 8. Verify that the output gear and idler are engaged properly. 9. Seat the harness wires on the casting channel. 10. Place the shim on the output shaft gear. 11. Press a NEW seal into the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Page 8005 12. Install the cover. Notice: Refer to Fastener Notice in Service Precautions. 13. Install 2 NEW screws (1) to the casting. ^ Tighten the screws to 2 Nm (18 inch lbs.). 14. Install 2 NEW longer screws (2) to the motor cover. ^ Tighten the screws to 3 Nm (26 inch lbs.). 15. Install the encoder motor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: Customer Interest Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set > Page 8014 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: All Technical Service Bulletins Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set > Page 8020 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-04-21-001 > May > 06 > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough Hose/Line HVAC: All Technical Service Bulletins A/C - Doesn't Blow Cold Enough Bulletin No.: 02-01-38-007C Date: July 27, 2004 TECHNICAL Subject: Poor A/C Performance - A/C Will Not Blow Cold Enough (Perform A/C System Checks, Replace Accumulator if Necessary) Models: 2002-2004 Chevrolet Silverado 2002-2004 GMC Sierra with 6.6L Diesel Engine (VINs 1, 2 - RPOs LB7, LLY) and Denso A/C Compressor Supercede: This bulletin is being revised to add part numbers for the hose, bracket and insulator to the Parts Information. Please discard Corporate Bulletin Number 02-01-38-007B (Section 01 - HVAC). Condition Some customers may comment on less than desirable A/C performance, especially when the ambient temperature is above 32°C (90°F). Correction Perform the following A/C system checks and replace the accumulator with P/N 89018601, if necessary. This new accumulator requires the accumulator bracket, the accumulator insulator and the A/C suction hose to be replaced also. ^ Check for A/C system leaks. ^ Check the A/C system for proper refrigerant charge. This requires recovering the refrigerant to determine charge in system. Refer to Refrigerant Recovery and Recharging in the HVAC sub-section of the Service Manual. ^ If no leaks were found and the A/C system is charged to specification, replace the accumulator using the procedure listed below. If normal diagnostics do not lead to a correction, then perform the following A/C system checks. 1. Re-calibrate the actuators. 2. Inspect the lower A/C condenser deflector for proper installation. The deflector should be positioned at the lower part of the condenser and extend forward into the top of the front bumper and below the two fresh air intake holes. 3. Check the engine cooling fan clutch for proper operation. 4. If the vehicle is equipped with a front license plate, inspect for proper installation. If the license plate bracket is installed upside down, it will block part of the two fresh air intake holes in the bumper. When the license plate bracket is installed correctly, the writing on the back of the bracket will be upside down. Inspect for material between the radiator and condenser. Remove the top plate to confirm that there is no restriction. A radiator front filled with material will decrease condenser performance. 5. Some improvements have been found by lowering the A/C charge from 0.82 kg (1.8 lbs) to 0.73 kg (1.6 lbs). 6. Check the low pressure cycling switch for proper operation. The low pressure switch opens at 172-234 kPa (25-34 psi) which stops compressor operation and closes when the low side pressure reaches 276-310 kPa (40-45 psi). This enables the compressor to turn back on. Important: Compressor clutch engagement cannot be used to determine the status of the low pressure switch. The low pressure switch is one of several inputs to the HVAC control module for A/C request authorization. A/C request is one of several inputs to the powertrain control module (PCM) that control A/C compressor clutch engagement. Using a scan tool to monitor low pressure switch status while monitoring the low side pressure with the ACR 2000 at the service port and watch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough > Page 8030 the pressure at which the switch opens/closes is imperative to successfully diagnosing the switch. 7. If the A/C performance has not improved after performing the above steps, replace the accumulator with P/N 89018601, using the procedure listed below. This new accumulator also requires the accumulator bracket, accumulator insulator and A/C suction hose to be replaced. Accumulator Replacement 1. Remove the suction hose mounting bolt from the A/C compressor. 2. Remove the suction hose from the compressor. 3. Remove the suction hose nut from the accumulator. 4. Remove the suction hose from the accumulator. 5. Remove the evaporator tube nut from the evaporator. 6. Remove the evaporator tube from the evaporator. 7. Disconnect the electrical connector from the A/C low pressure switch. 8. Remove the nut from the evaporator fitting. 9. Remove the accumulator bracket nut from the retaining stud. 10. Remove the accumulator. 11. Remove the retaining bracket bolt. This bolt must be reused for the new bracket. 12. Remove the insulator. One half of the insulator must be reused. 13. Install the new insulator and one half of the old insulator onto the new accumulator. 14. Install the new retaining bracket and bolt to the accumulator. Do not tighten at this time. 15. Add the PAG oil directly into the new accumulator that was removed during the recovery process plus an additional 90 ml (3 oz). 16. Install the new accumulator. 17. Install the accumulator bracket nut. Tighten Tighten the nut to 9 N.m (80 lb in). 18. Tighten the retaining bracket bolt. Tighten Tighten the nut to 10 N.m (89 lb in). 19. Install the nut to the evaporator fitting. Tighten Tighten the nut to 16 N.m (12 lb ft). 20. Install the evaporator tube to the evaporator. 21. Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N.m (12 lb ft). 22. Install the new suction hose to the accumulator. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough > Page 8031 23. Install the suction hose nut to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft). 24. Connect the electrical connector to the A/C low pressure switch. 25. Install the new suction hose to the compressor. 26. Install the suction hose mounting bolt to the A/C compressor. Tighten Tighten the bolt to 16 N.m (12 lb ft). Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough > Page 8037 the pressure at which the switch opens/closes is imperative to successfully diagnosing the switch. 7. If the A/C performance has not improved after performing the above steps, replace the accumulator with P/N 89018601, using the procedure listed below. This new accumulator also requires the accumulator bracket, accumulator insulator and A/C suction hose to be replaced. Accumulator Replacement 1. Remove the suction hose mounting bolt from the A/C compressor. 2. Remove the suction hose from the compressor. 3. Remove the suction hose nut from the accumulator. 4. Remove the suction hose from the accumulator. 5. Remove the evaporator tube nut from the evaporator. 6. Remove the evaporator tube from the evaporator. 7. Disconnect the electrical connector from the A/C low pressure switch. 8. Remove the nut from the evaporator fitting. 9. Remove the accumulator bracket nut from the retaining stud. 10. Remove the accumulator. 11. Remove the retaining bracket bolt. This bolt must be reused for the new bracket. 12. Remove the insulator. One half of the insulator must be reused. 13. Install the new insulator and one half of the old insulator onto the new accumulator. 14. Install the new retaining bracket and bolt to the accumulator. Do not tighten at this time. 15. Add the PAG oil directly into the new accumulator that was removed during the recovery process plus an additional 90 ml (3 oz). 16. Install the new accumulator. 17. Install the accumulator bracket nut. Tighten Tighten the nut to 9 N.m (80 lb in). 18. Tighten the retaining bracket bolt. Tighten Tighten the nut to 10 N.m (89 lb in). 19. Install the nut to the evaporator fitting. Tighten Tighten the nut to 16 N.m (12 lb ft). 20. Install the evaporator tube to the evaporator. 21. Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N.m (12 lb ft). 22. Install the new suction hose to the accumulator. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough > Page 8038 23. Install the suction hose nut to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft). 24. Connect the electrical connector to the A/C low pressure switch. 25. Install the new suction hose to the compressor. 26. Install the suction hose mounting bolt to the A/C compressor. Tighten Tighten the bolt to 16 N.m (12 lb ft). Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front > Page 8041 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 Speed Sensor: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8044 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8045 Speed Sensor: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Speed Sensor Replacement - Front Transfer Case Speed Sensor Replacement - Front Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the front speed sensor electrical connector (5). 3. Remove the front speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the front speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8046 2. Connect the front speed sensor electrical connector (5). 3. Install the transfer case shield, if equipped. Transfer Case Speed Sensor Replacement - Left Rear Transfer Case Speed Sensor Replacement - Left Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the left rear speed sensor electrical connector (4). 3. Remove the left rear speed sensor. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8047 1. Notice: Refer to Fastener Notice in Service Precautions. Install the left rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the left rear speed sensor electrical connector (4) 3. Lower the vehicle. Transfer Case Speed Sensor Replacement - Right Rear Transfer Case Speed Sensor Replacement - Right Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the right rear speed sensor electrical connector (3). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8048 3. Remove the right rear speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the right rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the right rear speed sensor electrical connector (3). 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8049 Speed Sensor: Service and Repair Transfer Case - NVG 261-NP2 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8050 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8051 Speed Sensor: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector. 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8052 2. Connect the speed sensor electrical connector. 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 8058 Transfer Case Actuator: Service and Repair Transfer Case Encoder Motor Replacement Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Disconnect the encoder motor electrical connector. 4. Remove the encoder motor bolts. 5. Remove the encoder motor. 6. Remove the actuator insulator gasket. 7. If replacing the encoder motor, remove the locating pins from the old motor. Installation Procedure Important: ^ If the encoder motor is being replaced because it is defective, ensure that the transfer case is in the neutral position. Manually shift the unit at the shift shaft. Use a crescent wrench, if necessary. ^ If the encoder motor is being replaced, a new gasket will come with the encoder motor. DO NOT reuse the old gasket. ^ A NEW encoder motor does NOT come with locating pins. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 8059 1. Install the locating pins to the NEW encoder motor. 2. Position a NEW actuator insulator gasket to the transfer case. 3. Install the encoder motor. Notice: Refer to Fastener Notice in Service Precautions. 4. Install encoder motor bolts. ^ Tighten the bolts, in the sequence shown, to 20 Nm (15 ft. lbs.). 5. Connect the encoder motor electrical connector. Ensure that the retention clips activate. 6. Install the front propeller shaft. 7. Install the transfer case shield, if equipped. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 Case Adapter: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Adapter Replacement Removal Procedure 1. Remove the transfer case. Refer to Transfer Case Assembly Replacement. 2. Remove the transfer case adapter bolts. 3. Remove the adapter. 4. Remove the adapter seal. Installation Procedure 1. Install a NEW seal onto the adapter. Important: Always use a new seal for the adapter. Do not use any type of sealant or adhesive in place of, or with the seal. 2. Install the adapter. Important: The transfer case adapter must be installed so that the adapter is evenly seated to the transmission before installing the retaining nuts. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the adapter bolts. ^ Tighten the bolts to 50 Nm (37 ft. lbs.). 4. Install the transfer case. Refer to Transfer Case Assembly Replacement. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8064 Case Adapter: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Adapter Replacement Removal Procedure 1. Remove the transfer case. 2. Support the transmission with a suitable jack stand. 3. Remove the transmission mount nuts. 4. Remove the crossmember bolts. 5. Remove the crossmember. 6. Remove the transmission mount bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8065 7. Remove the transmission mount. 8. Remove the transfer case adapter bolts. 9. Remove the transfer case adapter. 10. Remove the transfer case seal. 11. Remove the transfer case gasket, if necessary. Installation Procedure Important: If the gasket or the seal becomes damaged, replace it. DO NOT use any type of silicone sealer or liquid gasket maker in place of the seal or gasket. 1. Install a NEW transfer case adapter seal. 2. Install the transfer case adapter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8066 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the transfer case adapter bolts. ^ Tighten the bolts to 50 Nm (37 ft. lbs.). 4. Install the transmission mount. 5. Install the transmission mount bolts. ^ Tighten the bolts to 47 Nm (35 ft. lbs.). 6. Install the crossmember. 7. Install the crossmember bolts. ^ Tighten the bolts to 70 Nm (52 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8067 8. Install the transmission mount nuts. ^ Tighten the nuts to 40 Nm (30 ft. lbs.). 9. Remove the transmission jack. 10. Install a NEW transfer case gasket, if necessary. 11. Install the transfer case. 12. Check the fluid level. Add fluid if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8068 Case Adapter: Service and Repair Transfer Case - NVG 261-NP2 Transfer Case Adapter Replacement Removal Procedure 1. Remove the transfer case. 2. Lower the transmission slightly. 3. Remove the transfer case adapter bolts. 4. Remove the transfer case adapter. 5. Remove the transfer case adapter seal. 6. Remove the transfer case gasket, if necessary. Installation Procedure 1. Important: Always use a new gasket and seal for the transfer case and the transfer case adapter. Do not use any type of sealant or adhesive in place of or with the gasket or the seal. Install a NEW transfer case adapter seal. 2. Important: The transfer case adapter must be installed so that the adapter is evenly seated to the transmission before installing the retaining nuts. Position the transfer case adapter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8069 3. Notice: Refer to Fastener Notice in Service Precautions. Install the transfer case adapter bolts. ^ Tighten the bolts to 50 Nm (37 ft. lbs.). 4. Important: When installing the gasket to the transfer case, make sure that the yellow printing on the gasket is facing toward the transfer case (away from the transmission). The locating tab on the gasket should always be pointing up. Install the new transfer case gasket. 5. Install the transfer case. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8070 Case Adapter: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Adapter Replacement Removal Procedure 1. Remove the transfer case. 2. Remove the transfer case adapter bolts. 3. Remove the transfer case adapter. 4. Remove the transfer case adapter seal. 5. Remove the transfer case gasket, if necessary. Installation Procedure Important: If the gasket or the seal becomes damaged, replace it. DO NOT use any type of silicone sealer or liquid gasket maker in place of the seal or gasket. 1. Install a NEW transfer case adapter seal. 2. Install the transfer case adapter. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the transfer case adapter bolts. ^ Tighten the bolts to 50 Nm (37 ft. lbs.). 4. Install the transfer case. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 Case: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Shield Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield bolts, if equipped. 3. Remove the transfer case shield, if equipped. Installation Procedure 1. Position the transfer case shield, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the transfer case shield bolts, if equipped. ^ Tighten the bolts to 20 Nm (15 ft. lbs.). 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8075 Case: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Shield Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If the vehicle is a 1500 series, remove the transfer case shield bolts, if equipped. 3. Remove the transfer case shield, if equipped. 4. If the vehicle is a 2500 series, remove the transfer case shield screws, if equipped. 5. Remove the transfer case shield, if equipped. Installation Procedure 1. If the vehicle is a 2500 series, position the transfer case shield, if equipped. 2. Install the transfer case shield screws, if equipped. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8076 3. If the vehicle is a 1500 series, position the transfer case shield, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the transfer case shield bolts, if equipped. ^ Tighten the bolts/screws to 20 Nm (15 ft. lbs.). 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8077 Case: Service and Repair Transfer Case - NVG 261-NP2 Transfer Case Shield Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If the vehicle is a 1500 series, remove the transfer case shield bolts, if equipped. 3. Remove the transfer case shield, if equipped. 4. If the vehicle is a 2500 series, remove the transfer case shield screws, if equipped. 5. Remove the transfer case shield, if equipped. Installation Procedure 1. If the vehicle is a 2500 series, position the transfer case shield, if equipped. 2. Install the transfer case shield screws. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8078 3. If the vehicle is a 1500 series, position the transfer case shield, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the transfer case shield bolts, if equipped. ^ Tighten the bolts/screws to 20 Nm (15 ft. lbs.). 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8079 Case: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Shield Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield bolts, if equipped. 3. Remove the transfer case shield, if equipped. Installation Procedure 1. Position the transfer case shield to the crossmember, if equipped. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the transfer case shield bolts, if equipped. ^ Tighten the bolts to 20 Nm (15 ft. lbs.). 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 02-04-21-006E > Jul > 06 > AWD/4WD AWD/4WD Lamps/System Inop./DTC C0550 Control Module: Customer Interest AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 02-04-21-006E > Jul > 06 > AWD/4WD AWD/4WD Lamps/System Inop./DTC C0550 > Page 8088 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-04-21-006E > Jul > 06 > AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: All Technical Service Bulletins AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-04-21-006E > Jul > 06 > AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 > Page 8094 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-04-21-002 > Mar > 05 > Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-04-21-002 > Mar > 05 > Drivetrain - Transfer Case Control Module Replacement > Page 8099 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 07-08-44-016A > Aug > 07 > Entertainment System - DVD Monitor Display Inoperative DVD Player: All Technical Service Bulletins Entertainment System - DVD Monitor Display Inoperative Bulletin No.: 07-08-44-016A Date: August 28, 2007 TECHNICAL Subject: GM Accessories Headrest DVD System Display Monitor Inoperative (Install Cable Connector Clamps) Models Supercede: This bulletin is being revised to update the models affected list. Please discard Corporate Bulletin Number 07-08-44-016 (Section 08 - Body & Accessories). Condition Some customers may comment on an inoperative display monitor or monitors in the GM Accessories Headrest DVD System. Cause This condition may be caused by a loose connection at the display monitor cable connectors. These connectors are located at the lower rear part of both front seats. Two cables are routed to the display monitor in each seat. Correction A number of headrest monitors have been replaced under warranty and in many cases, no trouble was found by the supplier when these units were Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 07-08-44-016A > Aug > 07 > Entertainment System - DVD Monitor Display Inoperative > Page 8105 analyzed. Therefore, technicians should be checking for loose connections and installing cable connector clamps to ensure a positive and robust connection. Technicians are to install a video cable connector clamp on each cable connector located under each front seat. A total of four cable connector clamps, P/N 19159659, are required for each vehicle. The illustration above shows a pair of display monitor cable connectors without the cable clamps installed. The illustration above shows the display monitor cable connectors with the cable connector clamps. The lower cable connector clamp is installed but not locked together. The upper cable connector clamp is closed and locked. The cable connector clamps have now been added as a permanent component to all GM Accessories Headrest DVD Systems installation kits. Parts Information Warranty Information (excluding Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 07-08-44-016A > Aug > 07 > Entertainment System - DVD Monitor Display Inoperative > Page 8106 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 07-08-44-016A > Aug > 07 > Entertainment System - DVD Monitor Display Inoperative > Page 8112 analyzed. Therefore, technicians should be checking for loose connections and installing cable connector clamps to ensure a positive and robust connection. Technicians are to install a video cable connector clamp on each cable connector located under each front seat. A total of four cable connector clamps, P/N 19159659, are required for each vehicle. The illustration above shows a pair of display monitor cable connectors without the cable clamps installed. The illustration above shows the display monitor cable connectors with the cable connector clamps. The lower cable connector clamp is installed but not locked together. The upper cable connector clamp is closed and locked. The cable connector clamps have now been added as a permanent component to all GM Accessories Headrest DVD Systems installation kits. Parts Information Warranty Information (excluding Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 07-08-44-016A > Aug > 07 > Entertainment System - DVD Monitor Display Inoperative > Page 8113 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > NVG 246-NP8 Control Module: Locations NVG 246-NP8 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > NVG 246-NP8 > Page 8116 Control Module: Locations NVG 263-NP1 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 8117 Control Module: Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 8118 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 8119 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 Control Module: Service and Repair NVG 246-NP8 Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install new module before proceeding. Before reprogramming close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to do so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Disconnect the scan tool from the vehicle and connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to Program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Reconnect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 8122 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 8123 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 8124 Control Module: Service and Repair NVG 263-NP1 Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 8125 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install a new module before proceeding. Before reprogramming, close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to do so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 8126 Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information about the type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Connect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information about the type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case NVG 246 (RPO NP8) ........................................................................................................................... ........................................................... Not Specified NVG 261 (RPO NP2) ........................................ .............................................................................................................................................. Not Specified NVG 263 (RPO NPI) ............................................................................................................ ........................................................................... 1.9L (2.0 QT) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 8131 Fluid - Transfer Case: Fluid Type Specifications NVG 149-NP3 ................................................................................................... Manual Transmission Fliod GM P/N 8861800 (Canadian P/N 88861801) NVG 246-NP8 ......................................................................................... Auto-Trak II, transfer case fluid, GM P/N 12378508 (Canadian P/N 10953626) NVG 261-NP2 ................................................................................................... Manual Transmission Fliod GM P/N 8861800 (Canadian P/N 88861801) NVG 263-NP1 ................................................................................................... Manual Transmission Fliod GM P/N 8861800 (Canadian P/N 88861801) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 Fluid - Transfer Case: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Fluid Replacement Removal Procedure Important: When performing the following procedure, use only hand tools to remove and install the drain and fill plugs. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield, if equipped. 3. Remove the fill plug. 4. Remove the drain plug. Important: Ensure that an approved drain pan is used when draining the transfer case. 5. Allow the transfer case to drain completely. Installation Procedure 1. Install the drain plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Important: Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8134 2. Fill the transfer case to the bottom of the fill plug hole with DEXRON® III, GM P/N 12346143 (Canadian P/N 10952622). 3. Install the fill plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 4. Install the transfer case shield, if equipped. 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8135 Fluid - Transfer Case: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Fluid Replacement Removal Procedure Important: When performing the following procedures, use only hand tools to remove and install the drain and fill plugs. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transfer case shield, if equipped. 3. Remove the fill plug. 4. Remove the drain plug. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Important: Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case. Install the drain plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 2. Fill the transfer case to the bottom of the fill plug hole with Auto-Trak II, transfer case fluid, GM P/N 12378508 (Canadian P/N 10953626). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8136 3. Install the fill plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 4. Install the transfer case shield, if equipped. 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8137 Fluid - Transfer Case: Service and Repair Transfer Case - NVG 261-NP2 Transfer Case Fluid Replacement Removal Procedure Important: When performing the following service procedures, use only hand tools in order to remove and install the fill or drain plugs. Always start the plugs by hand in order to prevent cross threading. 1. Remove the transfer case shield, if equipped. 2. Remove the fill plug. 3. Remove the drain plug. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: If the drain or fill plug have to be replaced, use only aluminum replacement drain plugs. Steel plugs will react with the magnesium of the transfer case. 1. Install the drain plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 2. Fill the transfer case to the bottom of the fill plug hole with the approved transfer case fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8138 3. Install the fill plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 4. Install the transfer case shield, if equipped. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8139 Fluid - Transfer Case: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Fluid Replacement Removal Procedure Important: When performing the following procedure, use only hand tools to remove and install the drain and fill plugs. 1. Remove the transfer case shield, if equipped. 2. Remove the fill plug. 3. Remove the drain plug. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case. 1. Install the drain plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 2. Fill the transfer case to the bottom of the fill plug hole with the approved fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8140 3. Install the fill plug. ^ Tighten the plug to 20 Nm (15 ft. lbs.). 4. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Instrument Panel Switches-LH Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8144 Four Wheel Drive Selector Switch: Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8145 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Transfer Case - NVG 246-NP8 Four Wheel Drive Selector Switch: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (I/P) cluster bezel. 2. Using a flat-tipped screwdriver, gently pry the retaining clips open on the housing. 3. Slide out the selector switch until the electrical connector are accessible. 4. Disconnect the selector switch electrical connectors (2, 3). 5. Remove the selector switch from the housing. Installation Procedure 1. Position the selector switch close to the housing so the electrical connectors can be connected. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Transfer Case - NVG 246-NP8 > Page 8148 2. Connect the selector switch electrical connectors (2, 3). 3. Slide the selector switch into the housing until the switch snaps into place. Important: Make sure that the selector switch is seated properly in the housing before installing the I/P cluster bezel. 4. Install the I/P cluster bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Transfer Case - NVG 246-NP8 > Page 8149 Four Wheel Drive Selector Switch: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (IP) cluster bezel. 2. Pull the tabs on the side of the transfer case driver control switch out. 3. Pull the transfer case driver control switch straight out from the panel. Installation Procedure 1. Important: Make sure that the transfer case control switch is seated properly in the instrument panel before installing the instrument panel trim bezel. Install the transfer case driver control switch into the instrument panel. 2. Install the IP cluster bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear, Transfer Case > Component Information > Service and Repair Gear: Service and Repair Transfer Case Gear Indicator Switch Replacement Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the gear indicator switch electrical connector (2). 3. Remove the gear indicator switch. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the gear indicator switch. ^ Tighten the switch to 27 Nm (20 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear, Transfer Case > Component Information > Service and Repair > Page 8153 2. Connect the gear indicator switch electrical connector (2). 3. Install the transfer case shield, if equipped. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair Gear Sensor/Switch: Service and Repair Encoder Motor Sensor Replacement Removal Procedure Important: For ease of reassembly, shift the transfer case to 2HI prior to removing any components. 1. Remove the encoder motor. 2. Place the encoder motor on a clean work bench, 3. Remove the 2 screws (2) from the motor cover. 4. Remove the 2 screws (1) from the casting. 5. Remove the cover. 6. Remove and save the shim on the output gear. 7. Remove and discard the orange rubber seal from the cover. 8. Remove the output gear (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Page 8157 9. Disassemble the harness connector (1) from the encoder. 10. Remove the encoder from the output shaft using a flat tip screwdriver. Installation Procedure 1. Assemble the harness to the NEW encoder with the connector legend "TOP" (1) and the encoder part number facing up. 2. Assemble the output shaft into the encoder, being sure to align the encoder tab with the groove on the shaft. 3. Ensure the encoder is seating properly on the output gear. 4. Place the output shaft encoder on the casting. 5. Place the grommet harness on the casting slot, the flat area on the grommet will be facing up. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Page 8158 6. With the output gear encoder assembly in hand, carefully align the casting and output gear timing marks (1). 7. At the same time, be sure to align the encoder phasing post (1) with the phasing slot (2) in the casting and insert the shaft into the bushing. 8. Verify that the output gear and idler are engaged properly. 9. Seat the harness wires on the casting channel. 10. Place the shim on the output shaft gear. 11. Press a NEW seal into the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Page 8159 12. Install the cover. Notice: Refer to Fastener Notice in Service Precautions. 13. Install 2 NEW screws (1) to the casting. ^ Tighten the screws to 2 Nm (18 inch lbs.). 14. Install 2 NEW longer screws (2) to the motor cover. ^ Tighten the screws to 3 Nm (26 inch lbs.). 15. Install the encoder motor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises Output Shaft: Customer Interest Driveline - Bump/Clunk/Squawking Noises Bulletin No.: 01-04-17-004B Date: January 05, 2005 TECHNICAL Subject: Clunk, Bump or Squawk when Vehicle Comes to Complete Stop or Accelerating from Complete Stop (Replace Rear Drive Shaft Nickel-Plated Slip Yoke) Models Supercede: This bulletin is being revised to add Cadillac Escalade (Old Style) to the Models section. Please discard Corporate Bulletin Number 01-04-17-004A (Section 04 - Driveline/Axle). Condition Some customers may comment on a clunk, bump or squawk noise when the vehicle comes to a stop or when accelerating from a complete stop. Cause A slip/stick condition between the transfer case output shaft and the driveshaft slip yoke may cause this condition. Diagnostic Tips There are several resources in the electronic Service Information System which can provide the technician with information on diagnosis and repair of clunk conditions, and fix the customer's vehicle right the first time without unnecessary parts replacement. Some of the documents available in SI include: ^ Symptoms - Propeller Shaft Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8168 ^ Knock or Clunk Noise ^ Rear Drive Axle Noises (SI Document ID #700580) ^ Launch Shudder/Vibration on Acceleration (Replace Propeller Shaft and Install a New Pinion Flange/Seal), Bulletin # 02-04-17-001 ^ Information on 2-3 Upshift or 3-2 Downshift Clunk Noise, Bulletin # 01-07-30-042 ^ Driveline Clunk When Stopping (Reprogram Powertrain Control Module (PCM), Bulletin # 03-07-30-028 Correction Replace the rear drive shaft slip yoke with a new nickel-plated slip yoke. See the parts table below. Follow the service procedure below. 1. Raise the vehicle on a hoist. 2. Reference mark the propeller shaft to the pinion flange connection. Important: Do not pound on the propeller shaft yoke ears. Never pry or place any tool between a yoke and a universal joint. 3. Remove the bolts and the yoke retainers from the pinion flange. 4. Slide the propeller shaft forward and out of the rear pinion flange. 5. Lower the rear of the propeller shaft and pull the driveshaft out of the transfer case. Note: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 6. Support the propeller shaft in a line horizontal with the table of a press. Important: Remove the front slip yoke and the universal joint together. The new nickel-plated slip yoke comes with a new universal joint. 7. Disassemble the snap rings by pinching the ends together with a pair of pliers. 8. If the ring does not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the pressure from the ring. 9. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 in) hex head socket or a 27 mm (1-1/16 in) socket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8169 10. Place the J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 11. If you do not completely remove the bearing cup, lift the cross and insert the J 9522-5 between the seal and the bearing cup you are removing. Continue pressing the bearing cup out of the yoke. 12. Rotate the propeller shaft. Press the opposite bearing cup out of the drive shaft yoke. 13. Remove the old slip yoke and universal joint. 14. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 15. Inspect the bearing cup bores for burrs or imperfections. 16. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing into place or prevent the bearing retainers from properly seating. 17. Install the new nickel-plated slip yoke and universal joint. See parts table below for parts information. 18. Remove the bearing cups from the universal joint. 19. Assemble one bearing cup part way into one side of the yoke. Turn the yoke ear toward the bottom. 20. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8170 21. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 22. Install the opposite bearing cup part way into the yoke ear. 23. Ensure that the trunnions start straight and true into both bearing cups. 24. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for free unbinding movement of the trunnions in the bearing cups. Important: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for misalignment in the bearing cup. 25. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup. 26. Assemble the bearing retainer in the retainer groove. 27. Continue pressing until both retainers can be snapped into place. 28. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a soft-faced dead blow hammer. 29. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so that the snap ring seats in the bearing cup groove. 30. Install the slip yoke onto the output shaft in the transfer case. 31. Align the reference marks on the pinion flange and the propeller shaft. 32. Install the yoke retainers and bolts. Tighten Tighten the yoke retainer bolts to 25 N.m (19 lb ft). 33. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8171 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8172 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8173 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8174 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8175 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8176 Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8177 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises Output Shaft: All Technical Service Bulletins Driveline - Bump/Clunk/Squawking Noises Bulletin No.: 01-04-17-004B Date: January 05, 2005 TECHNICAL Subject: Clunk, Bump or Squawk when Vehicle Comes to Complete Stop or Accelerating from Complete Stop (Replace Rear Drive Shaft Nickel-Plated Slip Yoke) Models Supercede: This bulletin is being revised to add Cadillac Escalade (Old Style) to the Models section. Please discard Corporate Bulletin Number 01-04-17-004A (Section 04 - Driveline/Axle). Condition Some customers may comment on a clunk, bump or squawk noise when the vehicle comes to a stop or when accelerating from a complete stop. Cause A slip/stick condition between the transfer case output shaft and the driveshaft slip yoke may cause this condition. Diagnostic Tips There are several resources in the electronic Service Information System which can provide the technician with information on diagnosis and repair of clunk conditions, and fix the customer's vehicle right the first time without unnecessary parts replacement. Some of the documents available in SI include: ^ Symptoms - Propeller Shaft Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8183 ^ Knock or Clunk Noise ^ Rear Drive Axle Noises (SI Document ID #700580) ^ Launch Shudder/Vibration on Acceleration (Replace Propeller Shaft and Install a New Pinion Flange/Seal), Bulletin # 02-04-17-001 ^ Information on 2-3 Upshift or 3-2 Downshift Clunk Noise, Bulletin # 01-07-30-042 ^ Driveline Clunk When Stopping (Reprogram Powertrain Control Module (PCM), Bulletin # 03-07-30-028 Correction Replace the rear drive shaft slip yoke with a new nickel-plated slip yoke. See the parts table below. Follow the service procedure below. 1. Raise the vehicle on a hoist. 2. Reference mark the propeller shaft to the pinion flange connection. Important: Do not pound on the propeller shaft yoke ears. Never pry or place any tool between a yoke and a universal joint. 3. Remove the bolts and the yoke retainers from the pinion flange. 4. Slide the propeller shaft forward and out of the rear pinion flange. 5. Lower the rear of the propeller shaft and pull the driveshaft out of the transfer case. Note: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 6. Support the propeller shaft in a line horizontal with the table of a press. Important: Remove the front slip yoke and the universal joint together. The new nickel-plated slip yoke comes with a new universal joint. 7. Disassemble the snap rings by pinching the ends together with a pair of pliers. 8. If the ring does not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the pressure from the ring. 9. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 in) hex head socket or a 27 mm (1-1/16 in) socket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8184 10. Place the J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 11. If you do not completely remove the bearing cup, lift the cross and insert the J 9522-5 between the seal and the bearing cup you are removing. Continue pressing the bearing cup out of the yoke. 12. Rotate the propeller shaft. Press the opposite bearing cup out of the drive shaft yoke. 13. Remove the old slip yoke and universal joint. 14. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 15. Inspect the bearing cup bores for burrs or imperfections. 16. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing into place or prevent the bearing retainers from properly seating. 17. Install the new nickel-plated slip yoke and universal joint. See parts table below for parts information. 18. Remove the bearing cups from the universal joint. 19. Assemble one bearing cup part way into one side of the yoke. Turn the yoke ear toward the bottom. 20. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8185 21. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 22. Install the opposite bearing cup part way into the yoke ear. 23. Ensure that the trunnions start straight and true into both bearing cups. 24. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for free unbinding movement of the trunnions in the bearing cups. Important: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for misalignment in the bearing cup. 25. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup. 26. Assemble the bearing retainer in the retainer groove. 27. Continue pressing until both retainers can be snapped into place. 28. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a soft-faced dead blow hammer. 29. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so that the snap ring seats in the bearing cup groove. 30. Install the slip yoke onto the output shaft in the transfer case. 31. Align the reference marks on the pinion flange and the propeller shaft. 32. Install the yoke retainers and bolts. Tighten Tighten the yoke retainer bolts to 25 N.m (19 lb ft). 33. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8186 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8187 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8188 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8189 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8190 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8191 Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-04-17-004B > Jan > 05 > Driveline Bump/Clunk/Squawking Noises > Page 8192 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Output Shaft: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Adapter Kit: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Output Shaft: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 8198 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Output Shaft: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 8199 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Output Shaft: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 8205 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Output Shaft: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 8206 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 02-04-21-006E > Jul > 06 > AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: Customer Interest AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 02-04-21-006E > Jul > 06 > AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 > Page 8216 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-04-21-006E > Jul > 06 > AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: All Technical Service Bulletins AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-04-21-006E > Jul > 06 > AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 > Page 8222 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-04-21-002 > Mar > 05 > Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-04-21-002 > Mar > 05 > Drivetrain - Transfer Case Control Module Replacement > Page 8227 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > NHTSA04V045000 > Feb > 04 > Recall 04V045000: Possible Hydro-Boost Defect Power Steering Pump: All Technical Service Bulletins Recall 04V045000: Possible Hydro-Boost Defect DEFECT: Certain sport utility vehicles, pickup trucks, and passenger vans fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 135, "Passenger Car Brake Systems." Some of these vehicles were produced with an out-of-specification brake hydro-boost housing relief valve bore. Consequently, the valve O-ring seal may fracture. Steering efforts may be slightly increased while braking or parking. Under certain driving conditions, a fractured seal may also require an increase in the applied brake pedal effort to achieve the same vehicle deceleration. REMEDY: Dealers are to replace the hydro-boost relief valve. The manufacturer has reported that owner notification is expected to begin during the second quarter of 2004. Owners may contact Cadillac at 1-866-982-2339; Chevrolet at 1-800-630-2438; GMC at 1-866-996-9463; or Hummer at 1-866-486-6376. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > NVG 246-NP8 Control Module: Locations NVG 246-NP8 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > NVG 246-NP8 > Page 8240 Control Module: Locations NVG 263-NP1 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 8241 Control Module: Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 8242 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 8243 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 Control Module: Service and Repair NVG 246-NP8 Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install new module before proceeding. Before reprogramming close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to do so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Disconnect the scan tool from the vehicle and connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to Program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Reconnect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 8246 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 8247 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 8248 Control Module: Service and Repair NVG 263-NP1 Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 8249 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install a new module before proceeding. Before reprogramming, close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to do so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 8250 Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information about the type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Connect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information about the type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 Seals and Gaskets: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Output Shaft Seal Replacement - Front Transfer Case Output Shaft Seal Replacement - Front ^ Tools Required J 8092 Driver Handle - J 43484 Output Shaft Seal Installer Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Insert a flat-tipped screw driver into the inner race. 4. Pry the inner race back. 5. Insert a small pry bar into the inner race. Important: When performing the following service procedure, the outer part of the seal will slightly move out of the transfer case with the inner part seal. 6. Pry the inner part of the seal from the outer seal body. 7. Remove the inner part of the seal. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8255 8. Insert a flat-tipped screwdriver or small pry bar into the space between the lip of the outer race of the seal and the transfer case. 9. Pry the outer race out of the transfer case. 10. Remove the outer part of the seal. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8256 1. Install the J 43484 (2) to the J 8092 (1). 2. Install a NEW seal onto J 43484. 3. Using J 43484 (2), and J 8092 (1), install the seal. 4. Install the front propeller shaft. 5. Check the fluid level. Add fluid, if necessary. 6. Install the transfer case shield, if equipped. Transfer Case Output Shaft Seal Replacement - Rear Transfer Case Output Shaft Seal Replacement - Rear ^ Tools Required J 37668-A Output Shaft Seal Installer - J 45380 Transfer Case Rear Bushing Remover and Installer Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the rear propeller shaft. 3. Pry out the rear output shaft seal, using a flat-tipped screwdriver. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8257 4. Inspect the rear output shaft bushing for scoring or wear. 5. Remove the rear output shaft bushing if required, using the J 45380. ^ Install the finger section of the J 45380 into the front of the bushing. ^ Install the tube and forcing screw to the finger section. Ensure the forcing screw is backed out. ^ Using a wrench on the forcing screw, remove the rear output shaft bushing. Installation Procedure 1. Using the J 45380, install a NEW rear output shaft bushing. ^ Install the bushing or the finger section of the J 45380. ^ Install the finger section to the main body of the J 45380. ^ Position the bushing and tool to the case. ^ Using a hammer and the J 45380, install the bushing. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8258 2. Using the J 37668-A, install a NEW front output shaft seal. Important: Ensure the drain hole on the boot of the rear output shaft seal is facing down toward the ground. 3. Install the rear propeller shaft. 4. Check the fluid level. Add fluid, if necessary. 5. Install the transfer case shield, if equipped. Transfer Case Input Shaft Seal Replacement Transfer Case Input Shaft Seal Replacement ^ Tools Required J 42738 Front Output Shaft Seal Installer Removal Procedure 1. Remove the transfer case. 2. Remove the input shaft seal, using a flat-tipped screwdriver. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8259 1. Position the seal on the input shaft. Important: When installing the input shaft seal, make sure that the part numbers on the seal are facing outward (toward the technician). The input shaft seal should be even with the surface of the transfer case after installation. 2. Using the J 42738, install the input shaft seal. 3. Install the transfer case. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8260 Seals and Gaskets: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Output Shaft Seal Replacement - Front Transfer Case Output Shaft Seal Replacement - Front ^ Tools Required J 8092 Driver Handle - J 43484 Output Shaft Seal Installer Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Insert a flat-tipped screwdriver into the inner race. 4. Pry the inner race back. 5. Insert a small pry bar into the inner race. 6. Remove the inner part of the seal. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8261 7. Insert a flat-tipped screwdriver or a small pry bar in the space between the outer race of the seal and the transfer case. 8. Remove the outer part of the seal. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8262 1. Install the J 43484 (2) to the J 8092 (1). 2. Install the seal onto the J 43484. 3. Using the J 43484 (2) and the J 8092 (1), install the seal. 4. Install the front propeller shaft. 5. Check the fluid level, add fluid if necessary. 6. Install the transfer case shield, if equipped. Transfer Case Output Shaft Seal Replacement - Rear Transfer Case Output Shaft Seal Replacement - Rear ^ Tools Required J 37668-A Seal Installer - J 45380 Transfer Case Rear Bushing Remover and Installer Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the rear propeller shaft. 3. Remove the rear output shaft seal. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8263 4. Inspect the rear output shaft bushing for scoring or wear. 5. Remove the rear output shaft bushing if required, using the J 45380. ^ Install the finger section of the J 45380 in front of the bushing. ^ Install the tube and forcing screw to the finger section. Ensure the forcing screw is backed out. ^ Using a wrench on the forcing screw, remove the rear output shaft bushing. Installation Procedure 1. Install a NEW rear output shaft bushing, if required, using the J 45380. ^ Install the bushing or the finger section of the J 45380. ^ Install the finger section to the main body of the J 45380. ^ Position the bushing and tool to the case. ^ Using a hammer and the J 45380, install the bushing. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8264 2. Important: Ensure the drain hole on the boot of the rear output shaft seal is facing down toward the ground. Using the J 37668-A, install the rear output shaft to the transfer case. 3. Install the rear propeller shaft. 4. Check the fluid level, Add fluid if necessary. 5. Install the transfer case shield, if equipped. Transfer Case Input Shaft Seal Replacement Transfer Case Input Shaft Seal Replacement ^ Tools Required J 42738 Seal Installer Removal Procedure 1. Remove the transfer case. 2. Using a flat-tipped screwdriver, remove the input shaft seal. Installation Procedure Important: When installing the input shaft seal, make sure that the part numbers on the seal are facing outward (away from the body of the transfer case). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8265 1. Align the transfer case input shaft seal evenly on the input shaft. Important: The input shaft seal should be even with the surface of the transfer case after installation. 2. Using the J 42738, install the transfer case input shaft seal. 3. Install the transfer case. 4. Check the fluid level. Add fluid if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8266 Seals and Gaskets: Service and Repair Transfer Case - NVG 261-NP2 Transfer Case Output Shaft Seal Replacement - Front Transfer Case Output Shaft Seal Replacement - Front ^ Tools Required J 8092 Drive Handle - J 43484 Output Shaft Seal Installer Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Insert a flat-tipped screwdriver into the inner race. 4. Pry the inner race back. 5. Insert a small pry bar into the inner race. 6. Remove the inner part of the seal. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8267 7. Insert a flat-tipped screwdriver or a small pry bar in the space between the outer race of the seal and the transfer case. 8. Remove the outer part of the seal. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8268 1. Install the J 43484 (2) to the J 8092 (1). 2. Install the seal onto the J 43484 (2). 3. Using the J 43484 (2) and the J 8092 (1), install the seal. 4. Install the front propeller shaft. 5. Check the fluid level, add fluid if necessary. 6. Install the transfer case shield, if equipped. Transfer Case Output Shaft Seal Replacement - Rear Transfer Case Output Shaft Seal Replacement - Rear ^ Tools Required J 37668-A Seal Installer - J 45380 Transfer Case Rear Bushing Remover and Installer Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the rear propeller shaft. 3. Remove the rear output shaft seal. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8269 4. Inspect the rear output shaft bushing for scoring or wear. 5. Remove the rear output shaft bushing if required, using the J 45380. ^ Install the finger section of the J 45380 in front of the bushing. ^ Install the tube and forcing screw to the finger section. Ensure the forcing screw is backed out. ^ Using a wrench on the forcing screw, remove the rear output shaft bushing. Installation Procedure 1. Install a NEW rear output shaft bushing, if required, using the J 45380. ^ Install the bushing or the finger section of the J 45380. ^ Install the finger section to the main body of the J 45380. ^ Position the bushing and tool to the case. ^ Using a hammer and the J 45380, install the bushing. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8270 2. Important: Ensure the drain hole on the boot of the rear output shaft seal is facing down toward the ground. Using the J 37668-A, install the rear output shaft seal. 3. Install the rear propeller shaft. 4. Check the fluid level, add fluid if necessary. 5. Install the transfer case shield, if equipped. Transfer Case Input Shaft Seal Replacement Transfer Case Input Shaft Seal Replacement ^ Tools Required J 42738 Seal Installer Removal Procedure 1. Remove the transfer case. 2. using a flat-tipped screwdriver, remove the input shaft seal. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8271 1. Important: When installing the input shaft seal, make sure that the part numbers on the seal are facing outward (away from the body of the transfer case). Align the transfer case input shaft seal evenly on the input shaft. 2. Important: The input shaft seal should be even with the surface of the transfer case after installation. Using the J 42738, install the transfer case input shaft seal. 3. Install the transfer case. 4. Check the fluid level. Add fluid of necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8272 Seals and Gaskets: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Output Shaft Seal Replacement - Front Transfer Case Output Shaft Seal Replacement - Front ^ Tools Required J 8092 Driver Handle - J 43484 Output Shaft Seal Installer Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Insert a flat-tipped screwdriver into the inner race. 4. Pry the inner race back. 5. Insert a small pry bar into the inner race. 6. Remove the inner part of the seal. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8273 7. Insert a flat-tipped screwdriver or small pry bar in the space between the outer race of the seal and the transfer case. 8. Remove the outer part of the seal. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8274 1. Install the J 43484 (2) to the J 8092 (1). 2. Install the seal onto the J 43484 (2). 3. Using the J 43484 (2) and the J 8092 (1), install the seal. 4. Install the front propeller shaft. 5. Check the fluid level, add fluid if necessary. 6. Install the transfer case shield, if equipped. Transfer Case Output Shaft Seal Replacement - Rear Transfer Case Output Shaft Seal Replacement - Rear ^ Tools Required J 37668-A Seal Installer - J 45380 Transfer Case Rear Bushing Remover and Installer Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the rear propeller shaft. 3. Remove the rear output shaft seal. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8275 4. Inspect the rear output shaft bushing for scoring or wear. 5. Remove the rear output shaft bushing if required, using the J 45380 ^ Install the finger section of the J 45380 in front of the bushing. ^ Install the tube and forcing screw to the finger section. Ensure the forcing screw is backed out. ^ Using a wrench on the forcing screw, remove the rear output shaft bushing. Installation Procedure 1. Install a NEW rear output shaft bushing, if required using the J 45380 ^ Install the bushing or the finger section of the J 45380 ^ Install the finger section to the main body of the J 45380 ^ Position the bushing and tool to the case. ^ Using a hammer and the J 45380, install the bushing. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8276 2. Important: Ensure the drain hole on the boot of the rear output shaft seal is facing down toward the ground Using the J 37668-A, install the rear output shaft seal. 3. Install the rear propeller shaft. 4. Check the fluid level, add fluid if necessary. 5. Install the transfer case shield, if necessary. Transfer Case Input Shaft Seal Replacement Transfer Case Input Shaft Seal Replacement ^ Tools Required J 42738 Seal Installer Removal Procedure 1. Remove the transfer case. 2. Using a flat-tipped screwdriver, remove the input shaft seal. Installation Procedure Important: When installing the input shaft seal, make sure that the part numbers on the seal are facing outward (away from the body of the transfer case). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8277 1. Align the input seal evenly on the input shaft. Important: The input shaft seal should be even with the surface of the transfer case after installation. 2. Using the J 42738, install the input shaft seal. 3. Install the transfer case. 4. Check the fluid level, add fluid if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Instrument Panel Switches-LH Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8282 Four Wheel Drive Selector Switch: Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8283 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Transfer Case - NVG 246-NP8 Four Wheel Drive Selector Switch: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (I/P) cluster bezel. 2. Using a flat-tipped screwdriver, gently pry the retaining clips open on the housing. 3. Slide out the selector switch until the electrical connector are accessible. 4. Disconnect the selector switch electrical connectors (2, 3). 5. Remove the selector switch from the housing. Installation Procedure 1. Position the selector switch close to the housing so the electrical connectors can be connected. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Transfer Case - NVG 246-NP8 > Page 8286 2. Connect the selector switch electrical connectors (2, 3). 3. Slide the selector switch into the housing until the switch snaps into place. Important: Make sure that the selector switch is seated properly in the housing before installing the I/P cluster bezel. 4. Install the I/P cluster bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Transfer Case - NVG 246-NP8 > Page 8287 Four Wheel Drive Selector Switch: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Shift Control Switch Replacement Removal Procedure 1. Remove the instrument panel (IP) cluster bezel. 2. Pull the tabs on the side of the transfer case driver control switch out. 3. Pull the transfer case driver control switch straight out from the panel. Installation Procedure 1. Important: Make sure that the transfer case control switch is seated properly in the instrument panel before installing the instrument panel trim bezel. Install the transfer case driver control switch into the instrument panel. 2. Install the IP cluster bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair Gear Sensor/Switch: Service and Repair Encoder Motor Sensor Replacement Removal Procedure Important: For ease of reassembly, shift the transfer case to 2HI prior to removing any components. 1. Remove the encoder motor. 2. Place the encoder motor on a clean work bench, 3. Remove the 2 screws (2) from the motor cover. 4. Remove the 2 screws (1) from the casting. 5. Remove the cover. 6. Remove and save the shim on the output gear. 7. Remove and discard the orange rubber seal from the cover. 8. Remove the output gear (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Page 8291 9. Disassemble the harness connector (1) from the encoder. 10. Remove the encoder from the output shaft using a flat tip screwdriver. Installation Procedure 1. Assemble the harness to the NEW encoder with the connector legend "TOP" (1) and the encoder part number facing up. 2. Assemble the output shaft into the encoder, being sure to align the encoder tab with the groove on the shaft. 3. Ensure the encoder is seating properly on the output gear. 4. Place the output shaft encoder on the casting. 5. Place the grommet harness on the casting slot, the flat area on the grommet will be facing up. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Page 8292 6. With the output gear encoder assembly in hand, carefully align the casting and output gear timing marks (1). 7. At the same time, be sure to align the encoder phasing post (1) with the phasing slot (2) in the casting and insert the shaft into the bushing. 8. Verify that the output gear and idler are engaged properly. 9. Seat the harness wires on the casting channel. 10. Place the shim on the output shaft gear. 11. Press a NEW seal into the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Page 8293 12. Install the cover. Notice: Refer to Fastener Notice in Service Precautions. 13. Install 2 NEW screws (1) to the casting. ^ Tighten the screws to 2 Nm (18 inch lbs.). 14. Install 2 NEW longer screws (2) to the motor cover. ^ Tighten the screws to 3 Nm (26 inch lbs.). 15. Install the encoder motor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: Customer Interest Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set > Page 8302 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: All Technical Service Bulletins Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set > Page 8308 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-04-21-001 > May > 06 > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises Slip Yoke: All Technical Service Bulletins Driveline - Bump/Clunk/Squawking Noises Bulletin No.: 01-04-17-004B Date: January 05, 2005 TECHNICAL Subject: Clunk, Bump or Squawk when Vehicle Comes to Complete Stop or Accelerating from Complete Stop (Replace Rear Drive Shaft Nickel-Plated Slip Yoke) Models Supercede: This bulletin is being revised to add Cadillac Escalade (Old Style) to the Models section. Please discard Corporate Bulletin Number 01-04-17-004A (Section 04 - Driveline/Axle). Condition Some customers may comment on a clunk, bump or squawk noise when the vehicle comes to a stop or when accelerating from a complete stop. Cause A slip/stick condition between the transfer case output shaft and the driveshaft slip yoke may cause this condition. Diagnostic Tips There are several resources in the electronic Service Information System which can provide the technician with information on diagnosis and repair of clunk conditions, and fix the customer's vehicle right the first time without unnecessary parts replacement. Some of the documents available in SI include: ^ Symptoms - Propeller Shaft Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8318 ^ Knock or Clunk Noise ^ Rear Drive Axle Noises (SI Document ID #700580) ^ Launch Shudder/Vibration on Acceleration (Replace Propeller Shaft and Install a New Pinion Flange/Seal), Bulletin # 02-04-17-001 ^ Information on 2-3 Upshift or 3-2 Downshift Clunk Noise, Bulletin # 01-07-30-042 ^ Driveline Clunk When Stopping (Reprogram Powertrain Control Module (PCM), Bulletin # 03-07-30-028 Correction Replace the rear drive shaft slip yoke with a new nickel-plated slip yoke. See the parts table below. Follow the service procedure below. 1. Raise the vehicle on a hoist. 2. Reference mark the propeller shaft to the pinion flange connection. Important: Do not pound on the propeller shaft yoke ears. Never pry or place any tool between a yoke and a universal joint. 3. Remove the bolts and the yoke retainers from the pinion flange. 4. Slide the propeller shaft forward and out of the rear pinion flange. 5. Lower the rear of the propeller shaft and pull the driveshaft out of the transfer case. Note: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 6. Support the propeller shaft in a line horizontal with the table of a press. Important: Remove the front slip yoke and the universal joint together. The new nickel-plated slip yoke comes with a new universal joint. 7. Disassemble the snap rings by pinching the ends together with a pair of pliers. 8. If the ring does not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the pressure from the ring. 9. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 in) hex head socket or a 27 mm (1-1/16 in) socket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8319 10. Place the J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 11. If you do not completely remove the bearing cup, lift the cross and insert the J 9522-5 between the seal and the bearing cup you are removing. Continue pressing the bearing cup out of the yoke. 12. Rotate the propeller shaft. Press the opposite bearing cup out of the drive shaft yoke. 13. Remove the old slip yoke and universal joint. 14. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 15. Inspect the bearing cup bores for burrs or imperfections. 16. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing into place or prevent the bearing retainers from properly seating. 17. Install the new nickel-plated slip yoke and universal joint. See parts table below for parts information. 18. Remove the bearing cups from the universal joint. 19. Assemble one bearing cup part way into one side of the yoke. Turn the yoke ear toward the bottom. 20. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8320 21. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 22. Install the opposite bearing cup part way into the yoke ear. 23. Ensure that the trunnions start straight and true into both bearing cups. 24. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for free unbinding movement of the trunnions in the bearing cups. Important: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for misalignment in the bearing cup. 25. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup. 26. Assemble the bearing retainer in the retainer groove. 27. Continue pressing until both retainers can be snapped into place. 28. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a soft-faced dead blow hammer. 29. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so that the snap ring seats in the bearing cup groove. 30. Install the slip yoke onto the output shaft in the transfer case. 31. Align the reference marks on the pinion flange and the propeller shaft. 32. Install the yoke retainers and bolts. Tighten Tighten the yoke retainer bolts to 25 N.m (19 lb ft). 33. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8321 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8322 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8323 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8324 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8325 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8326 Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8327 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8333 ^ Knock or Clunk Noise ^ Rear Drive Axle Noises (SI Document ID #700580) ^ Launch Shudder/Vibration on Acceleration (Replace Propeller Shaft and Install a New Pinion Flange/Seal), Bulletin # 02-04-17-001 ^ Information on 2-3 Upshift or 3-2 Downshift Clunk Noise, Bulletin # 01-07-30-042 ^ Driveline Clunk When Stopping (Reprogram Powertrain Control Module (PCM), Bulletin # 03-07-30-028 Correction Replace the rear drive shaft slip yoke with a new nickel-plated slip yoke. See the parts table below. Follow the service procedure below. 1. Raise the vehicle on a hoist. 2. Reference mark the propeller shaft to the pinion flange connection. Important: Do not pound on the propeller shaft yoke ears. Never pry or place any tool between a yoke and a universal joint. 3. Remove the bolts and the yoke retainers from the pinion flange. 4. Slide the propeller shaft forward and out of the rear pinion flange. 5. Lower the rear of the propeller shaft and pull the driveshaft out of the transfer case. Note: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 6. Support the propeller shaft in a line horizontal with the table of a press. Important: Remove the front slip yoke and the universal joint together. The new nickel-plated slip yoke comes with a new universal joint. 7. Disassemble the snap rings by pinching the ends together with a pair of pliers. 8. If the ring does not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the pressure from the ring. 9. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 in) hex head socket or a 27 mm (1-1/16 in) socket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8334 10. Place the J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 11. If you do not completely remove the bearing cup, lift the cross and insert the J 9522-5 between the seal and the bearing cup you are removing. Continue pressing the bearing cup out of the yoke. 12. Rotate the propeller shaft. Press the opposite bearing cup out of the drive shaft yoke. 13. Remove the old slip yoke and universal joint. 14. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 15. Inspect the bearing cup bores for burrs or imperfections. 16. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing into place or prevent the bearing retainers from properly seating. 17. Install the new nickel-plated slip yoke and universal joint. See parts table below for parts information. 18. Remove the bearing cups from the universal joint. 19. Assemble one bearing cup part way into one side of the yoke. Turn the yoke ear toward the bottom. 20. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8335 21. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 22. Install the opposite bearing cup part way into the yoke ear. 23. Ensure that the trunnions start straight and true into both bearing cups. 24. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for free unbinding movement of the trunnions in the bearing cups. Important: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for misalignment in the bearing cup. 25. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup. 26. Assemble the bearing retainer in the retainer groove. 27. Continue pressing until both retainers can be snapped into place. 28. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a soft-faced dead blow hammer. 29. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so that the snap ring seats in the bearing cup groove. 30. Install the slip yoke onto the output shaft in the transfer case. 31. Align the reference marks on the pinion flange and the propeller shaft. 32. Install the yoke retainers and bolts. Tighten Tighten the yoke retainer bolts to 25 N.m (19 lb ft). 33. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8336 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8337 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8338 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8339 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8340 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8341 Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 01-04-17-004B > Jan > 05 > Driveline - Bump/Clunk/Squawking Noises > Page 8342 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front > Page 8345 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 Speed Sensor: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8348 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8349 Speed Sensor: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Speed Sensor Replacement - Front Transfer Case Speed Sensor Replacement - Front Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the front speed sensor electrical connector (5). 3. Remove the front speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the front speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8350 2. Connect the front speed sensor electrical connector (5). 3. Install the transfer case shield, if equipped. Transfer Case Speed Sensor Replacement - Left Rear Transfer Case Speed Sensor Replacement - Left Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the left rear speed sensor electrical connector (4). 3. Remove the left rear speed sensor. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8351 1. Notice: Refer to Fastener Notice in Service Precautions. Install the left rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the left rear speed sensor electrical connector (4) 3. Lower the vehicle. Transfer Case Speed Sensor Replacement - Right Rear Transfer Case Speed Sensor Replacement - Right Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the right rear speed sensor electrical connector (3). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8352 3. Remove the right rear speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the right rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the right rear speed sensor electrical connector (3). 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8353 Speed Sensor: Service and Repair Transfer Case - NVG 261-NP2 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8354 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8355 Speed Sensor: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector. 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8356 2. Connect the speed sensor electrical connector. 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: Customer Interest Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set > Page 8365 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: All Technical Service Bulletins Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set > Page 8371 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 06-04-21-001 > May > 06 > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 06-04-21-001 > May > 06 > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front > Page 8383 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 Speed Sensor: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8386 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8387 Speed Sensor: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Speed Sensor Replacement - Front Transfer Case Speed Sensor Replacement - Front Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the front speed sensor electrical connector (5). 3. Remove the front speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the front speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8388 2. Connect the front speed sensor electrical connector (5). 3. Install the transfer case shield, if equipped. Transfer Case Speed Sensor Replacement - Left Rear Transfer Case Speed Sensor Replacement - Left Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the left rear speed sensor electrical connector (4). 3. Remove the left rear speed sensor. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8389 1. Notice: Refer to Fastener Notice in Service Precautions. Install the left rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the left rear speed sensor electrical connector (4) 3. Lower the vehicle. Transfer Case Speed Sensor Replacement - Right Rear Transfer Case Speed Sensor Replacement - Right Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the right rear speed sensor electrical connector (3). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8390 3. Remove the right rear speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the right rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the right rear speed sensor electrical connector (3). 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8391 Speed Sensor: Service and Repair Transfer Case - NVG 261-NP2 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8392 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8393 Speed Sensor: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector. 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8394 2. Connect the speed sensor electrical connector. 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 8398 Transfer Case Actuator: Service and Repair Transfer Case Encoder Motor Replacement Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Disconnect the encoder motor electrical connector. 4. Remove the encoder motor bolts. 5. Remove the encoder motor. 6. Remove the actuator insulator gasket. 7. If replacing the encoder motor, remove the locating pins from the old motor. Installation Procedure Important: ^ If the encoder motor is being replaced because it is defective, ensure that the transfer case is in the neutral position. Manually shift the unit at the shift shaft. Use a crescent wrench, if necessary. ^ If the encoder motor is being replaced, a new gasket will come with the encoder motor. DO NOT reuse the old gasket. ^ A NEW encoder motor does NOT come with locating pins. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 8399 1. Install the locating pins to the NEW encoder motor. 2. Position a NEW actuator insulator gasket to the transfer case. 3. Install the encoder motor. Notice: Refer to Fastener Notice in Service Precautions. 4. Install encoder motor bolts. ^ Tighten the bolts, in the sequence shown, to 20 Nm (15 ft. lbs.). 5. Connect the encoder motor electrical connector. Ensure that the retention clips activate. 6. Install the front propeller shaft. 7. Install the transfer case shield, if equipped. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Clutch > Component Information > Technical Service Bulletins > Transfer Case - 1st & 2nd Clutch Hub & Apply Plate Transfer Case Clutch: Technical Service Bulletins Transfer Case - 1st & 2nd Clutch Hub & Apply Plate Bulletin No.: 05-04-21-005 Date: August 03, 2005 INFORMATION Subject: First and Second Design Clutch Hub and Apply Plate for NV246 Transfer Case Models: 1999-2004 Chevrolet Full Size Pickups and Utilities 1999-2004 GMC Full Size Pickups and Utilities with NV246 Transfer Case (RPO NP8) If service requires replacement of the first design Clutch Hub (17) that is no longer available form GMSPO ,the second design Clutch Hub (17) requires a second design Apply Plate (18) also be replaced in order to obtain proper stack up height in the transfer case. ^ 1999-2002 vehicles that require replacement of the Clutch Hub (17), P/N 88962324 second design also require the Apply Plate (18), P/N 88962331 second design to be replaced at the same time in order to obtain proper stack up height in the transfer case. ^ 2003-2004 vehicles that require replacement of the Clutch Hub (17), P/N 88962324 second design also require the Apply Plate (18), P/N 88962327 second design to be replaced at the same time in order to obtaining proper stack up height in the transfer case. Important: ^ A clutch plate shim package is necessary in order to have the proper shims available for setting the correct clutch pack preload. Improper preload may cause driveability concerns and failure of the transfer case. ^ Transfer case shims are available from GMSPO. Refer to Corporate Bulletin Number 04-04-21-003. ^ Whenever the second design Clutch Hub and the second design Apply Plate are used, a revised stack height will have to be used. This implements a shim J-44295-4 (0.085 in. thick) in conjunction with the clutch pack shimming kit J-44295 to achieve the correct stack height. Refer to SI Unit Repair, Transfer Case Assemble. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Clutch > Component Information > Technical Service Bulletins > Transfer Case - 1st & 2nd Clutch Hub & Apply Plate > Page 8404 Transfer Case Clutch: Technical Service Bulletins Drivetrain - Transfer Case Clutch Shimming Bulletin No.: 04-04-21-003 Date: November 10, 2004 INFORMATION Subject: Automatic Transfer Case Clutch Plate Shimming - Parts Availability Change Models: 1999-2000 Cadillac Escalade 1998-2005 Chevrolet Blazer 1999-2005 Chevrolet Astro Van, Silverado, Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1998-2005 GMC Jimmy 1999 GMC Suburban 1999-2005 GMC Safari Van, Sierra, Yukon, Yukon XL 1998-2001 Oldsmobile Bravada with NV 136/236/246 Automatic Transfer Case (RPO NP4 or NP8) While performing the transfer case clutch shimming procedure found in Service Information (SI), you may find it necessary to replace the clutch pack selective fit shim to obtain the correct clutch pack clearance. The selective fit shims for this repair were previously released as a kit, P/N 12474121, which contained all eight selective fit sizes. Effective immediately, the clutch pack shims will be available individually as listed below. The shim kit, P/N 12474121, will be discontinued and no longer available once current stock has been depleted. Parts Information Parts are currently available from GMSPO. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Component Locations Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Component Locations > Page 8412 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 8413 Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement ^ Tools Required J 36850 Transjel Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission filter. 3. Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. Remove the reverse boost valve bushing retainer ring (2). 4. Remove the following from the reverse boost valve cylinder: ^ The reverse boost valve bushing ^ The reverse boost valve ^ The pressure regulator spring retainer ^ The pressure regulator spring ^ The pressure regulator valve ^ The reverse boost valve bushing Installation Procedure 1. Install the pressure regulator valve using J 36850. 2. Pre-assemble the following parts: ^ The reverse boost valve bushing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 8414 ^ A new reverse boost valve ^ A new pressure regulator spring retainer ^ The added isolator pressure regulator spring ^ The pressure regulator spring 3. Install the pre-assembled parts into the pump bore. 4. Install the reverse boost valve bushing retainer ring while holding the reverse boost valve bushing in place. Ensure the retainer ring (2) is in the groove. 5. Install the transmission filter. 6. Fill the transmission to the proper level with Dexron® III transmission fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 8418 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure 1. Caution: Refer to SIR Caution in Service Precautions. Disable the SIR system. 2. Remove the body control module (BCM). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Diagrams > Page 8419 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the BCM. 6. Enable the SIR system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Electrical Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Electrical Specifications > Page 8424 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 8425 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E Shift Solenoid: Diagrams Automatic Transmission - 4L80-E/4L85-E Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 8428 Shift Solenoid: Diagrams Automatic Transmission - Allison Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 8429 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 8430 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 8431 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 8432 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 8433 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 8434 Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. 2. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. Remove the 1-2 accumulator, if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 8435 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 8436 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395). 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Notice: Refer to Fastener Notice in Service Precautions. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 8437 6. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 8442 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 8443 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Remove the transmission filter. 2. Disconnect the transmission harness 20-way connector (1) from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. 3. Important: Removal of the valve body is not necessary for the following procedure. Remove the 1-2 accumulator. Do not remove the spacer plate. 4. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ Torque converter clutch pulse width modulation (TCC PWM) solenoid (5) ^ 3-2 control solenoid (6) 5. Remove the TCC PWM solenoid retainer. 6. Remove the TCC PWM solenoid in order to access one of the TCC solenoid bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 8444 7. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 8. Remove the pressure control solenoid (377). 9. Remove the TCC solenoid bolts and the valve body bolts which retain the internal wiring harness. 10. Using J 28458 , release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the four tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 8445 12. Inspect the TCC solenoid and wiring harness for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid bolts. ^ Tighten the control valve body bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid bolts to 11 Nm (97 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 8446 4. Important: When installing the pressure control solenoid, the electrical connector (2) must be in the position shown. Install the pressure control solenoid (377). 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). ^ Tighten the bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 8447 ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector (1) to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 8452 Transfer Case Actuator: Service and Repair Transfer Case Encoder Motor Replacement Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Remove the front propeller shaft. 3. Disconnect the encoder motor electrical connector. 4. Remove the encoder motor bolts. 5. Remove the encoder motor. 6. Remove the actuator insulator gasket. 7. If replacing the encoder motor, remove the locating pins from the old motor. Installation Procedure Important: ^ If the encoder motor is being replaced because it is defective, ensure that the transfer case is in the neutral position. Manually shift the unit at the shift shaft. Use a crescent wrench, if necessary. ^ If the encoder motor is being replaced, a new gasket will come with the encoder motor. DO NOT reuse the old gasket. ^ A NEW encoder motor does NOT come with locating pins. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 8453 1. Install the locating pins to the NEW encoder motor. 2. Position a NEW actuator insulator gasket to the transfer case. 3. Install the encoder motor. Notice: Refer to Fastener Notice in Service Precautions. 4. Install encoder motor bolts. ^ Tighten the bolts, in the sequence shown, to 20 Nm (15 ft. lbs.). 5. Connect the encoder motor electrical connector. Ensure that the retention clips activate. 6. Install the front propeller shaft. 7. Install the transfer case shield, if equipped. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Maintenance Indicator - A/T > Component Information > Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation PRNDL DISPLAY The IPC displays the selected gear position as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the gear position. The PRNDL display blanks if: - The IPC receives a class 2 message indicating the park position and the column park switch indicates a position other than park, open input. - The IPC detects a loss of class 2 communications with the PCM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Transmission Control Module Replacement Control Module: Service and Repair Transmission Control Module Replacement Transmission Control Module (TCM) Replacement Removal Procedure Important: ^ Remove any debris from the transmission control module(TCM) connector surfaces before servicing the TCM. Inspect the TCM module connector gaskets when diagnosing or replacing the TCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the TCM. ^ The ignition must be OFF when disconnecting or reconnecting power to the TCM. 1. Disconnect the negative battery cable. 2. Remove the TCM cover bolts (1) located on the left side of the radiator shroud. 3. Pull the cover and TCM up and away from the radiator shroud. 4. Push up on the retainers (1) in order to remove the TCM from the cover. 5. Disconnect the TCM electrical connectors (2) and remove the TCM from the vehicle. Installation Procedure 1. Connect the TCM electrical connectors (2) to the TCM. 2. Install the TCM to the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Transmission Control Module Replacement > Page 8468 3. Using the alignment tabs (1), install the cover and module to the radiator shroud. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the TCM cover bolts (1) to the radiator shroud. ^ Tighten the bolts to 9 Nm (80 inch lbs.). 5. Connect the negative battery cable. 6. Reprogram the TCM. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Transmission Control Module Replacement > Page 8469 Control Module: Service and Repair Transmission Control Module Reprogramming Procedures Transmission Control Module Reprogramming Procedures Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install new module before proceeding. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the Electronic Control Unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to Program/Reprogram. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Reconnect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the Electronic Control Unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to Program/Reprogram. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 02-04-21-006E > Jul > 06 > AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: Customer Interest AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 02-04-21-006E > Jul > 06 > AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 > Page 8479 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 02-04-21-006E > Jul > 06 > AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Control Module: All Technical Service Bulletins AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 Bulletin No.: 02-04-21-006E Date: July 20, 2006 TECHNICAL Subject: Inoperative 4WD/AWD Lamps, Inoperative 4WD/AWD System, DTC C0550 Set, No Communication with TCCM (Reprogram Transfer Case Control Module) Models: 2004 Buick Rainier 2002-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2004 GMC Envoy, Envoy XL 2003-2004 GMC Sierra, Yukon, Yukon XL 2004 GMC Envoy XUV 2002-2004 Oldsmobile Bravada with Electronic Shift or Active Transfer Case (RPOs NP1, NP4 or NP8) Supercede: This bulletin is being revised to add Subject information and change the labor operation. This bulletin cancels and supersedes Bulletin Number 03-04-21-006. Please discard Corporate Bulletin Numbers 02-04-21-006D and 03-04-21-006 (Section 04 - Driveline/Axle). Condition Some customers may comment that the 4WD/AWD indicator lights on the selector switch do not work, or the 4WD/AWD system may be inoperative and/or the service 4WD light is illuminated. The condition is typically intermittent and always occurs at key-up. Upon investigation, the technician may find DTC C0550 set. Cause The Transfer Case Control Module (TCCM) has not received the wake-up call during key-up and has remained in the "sleep mode". When the TCCM is in the "sleep mode", it will not communicate with the class II bus or the Tech 2(R). Correction 1. Try to communicate with the TCCM. If no communication, go to step 2. If communication is possible, go to step 5. 2. Remove the underhood (ATCM or TREC) TCCM fuse. 3. Wait 30 seconds. 4. Reinstall the fuse. The module should wake up and communicate with the Tech 2(R). 5. Check for codes in the TCCM. If a C0550 is found current or in history with or without other codes, replace the module and go to step 6. 6. Reprogram the TCCM with the latest TIS software using normal SPS procedures. 7. Verify operation and that no codes are present. Important: For the 2002 model year, the TCCM must be replaced and reprogrammed. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 02-04-21-006E > Jul > 06 > AWD/4WD - AWD/4WD Lamps/System Inop./DTC C0550 > Page 8485 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 05-04-21-002 > Mar > 05 > Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 05-04-21-002 > Mar > 05 > Drivetrain - Transfer Case Control Module Replacement > Page 8490 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 05-04-21-002 > Mar > 05 > Drivetrain - Transfer Case Control Module Replacement Control Module: All Technical Service Bulletins Drivetrain - Transfer Case Control Module Replacement Bulletin No.: 05-04-21-002 Date: March 10, 2005 INFORMATION Subject: Guidelines for Replacement of Transfer Case Control Module (TCCM) Models: 2005 and Prior Light Duty Trucks with New Venture Gear (NVG) Transfer Case (RPOs NP1, NP4, NP8) Dealers are replacing the TCCM unnecessarily. Dealers are replacing the TCCM with codes stored in HISTORY only. The TCCM does not have a current fault condition when tested. Parts reviewed at the Warranty Parts Center (WPC) have a 75% No Trouble Found (NTF) rate. The only two legitimate reasons to replace the TCCM are: ^ Diagnostic Trouble Code (DTC) C0550 ^ NO Communication with a scan tool. DTC C0550 This DTC indicates that the module has an internal fault and should be replaced. No Communication ^ The no communication conditions referenced here are also caused by a module internal fault to a point where the module physically will not talk. A technician cannot pull DTCs from the module because it will not communicate. The module is electrically dead. ^ No communication is not to be confused with a U1026 code. This code tells the technician that the module may still be functioning but is temporarily off line. This code may be set by the Instrument Panel (IP) or the Powertrain Control Module (PCM) against the TCCM. The technician needs to figure out why the module went off line. These are typically caused by connection concerns. There is no need to replace a TCCM for a U1026 DTC. Diagnostic Aids ^ When diagnosing a transfer case electrical control system, ALWAYS check power and ground wiring first. ^ Test the connections for intermittent or poor connections, complete plug insertion, bent pins, pushed out terminals and water contamination. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 05-04-21-002 > Mar > 05 > Drivetrain - Transfer Case Control Module Replacement > Page 8496 Pay particular attention to the terminal connections at the module. Spread or open terminal connections may create an intermittent contact. Do a pin drag test. Refer to the terminal testing information in the table shown. ^ After repairs are complete, ALWAYS clear DTCs from the module prior to a system function test. If codes are not cleared first, the system will not function after repair. The technician may erroneously think that the system is still down and that further repairs are needed. Warranty Dealers who unnecessarily replace the TCCM that are found to have No Trouble Found (NTF) at the WPC will be returned to the AVM (Area Service Manager), or the DSM (District Service Manager) in Canada, through the Regional Feedback Process and may be charged back for the repair through the WINS system. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > NVG 246-NP8 Control Module: Locations NVG 246-NP8 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > NVG 246-NP8 > Page 8499 Control Module: Locations NVG 263-NP1 Transfer Case Shift Control Module Transfer Case Shift Control Module 1 - I/P Harness 2 - Transfer Case Shift Control Module Connectors 3 - Transfer Case Shift Control Module 4 - Instrument Panel Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 8500 Control Module: Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 8501 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 8502 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 Control Module: Service and Repair NVG 246-NP8 Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install new module before proceeding. Before reprogramming close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to do so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Disconnect the scan tool from the vehicle and connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to Program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Reconnect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information as to what type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 8505 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 8506 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 8507 Control Module: Service and Repair NVG 263-NP1 Transfer Case Shift Control Module Replacement Transfer Case Shift Control Module Replacement Removal Procedure 1. Disconnect the shift control module electrical connectors. 2. Unsnap and remove the shift control module from the bracket. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 8508 1. If a NEW control module is being installed, program the new module. 2. Install the shift control module to the bracket. 3. Connect the shift control module electrical connectors. 4. Start the engine and test the automatic transfer case system for proper shift operation. Transfer Case Control Module Reprogramming Transfer Case Control Module Reprogramming Set-up for Module Programming/Reprogramming Important: Ensure that the vehicle battery is fully charged and that a battery charger is no longer connected. If performing this procedure for module replacement, install a new module before proceeding. Before reprogramming, close the doors and wait two minutes to allow other modules to stop communicating via the class 2 data line. Failure to do so could result in a failed reprogramming procedure. ^ Turn OFF all accessories. ^ Turn ON the ignition, with the engine OFF. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > NVG 246-NP8 > Page 8509 Remote Programming Feature 1. Connect the scan tool to the vehicle. 2. Power-up the scan tool and select the Service Programming feature. 3. Select the appropriate vehicle. 4. Press the Request Info button on the scan tool. 5. Connect the scan tool to the computer station. 6. Follow the menu select items for reprogramming and provide information about the type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 7. Select "vehicle" from the selection menu. 8. Select the module you wish to program. 9. Select "Normal" for Programming Type. 10. Select the applicable software calibrations. 11. Transfer data file to the scan tool. 12. Connect the scan tool to the vehicle. 13. Turn ON the ignition, with the engine OFF. 14. Select the Service Programming feature on the scan tool. 15. Press the Program button on the scan tool. Programming Using Scan Tool Pass-Through Connection 1. Connect the scan tool to vehicle and power it up. 2. Connect the computer station to the scan tool. 3. Select "PC Using Scan Tool Connection" from the programming menu on the computer station. 4. Follow the menu select items for reprogramming and provide information about the type of device you are programming and whether you are reprogramming or replacing the electronic control unit (ECU). 5. Select "vehicle" from the selection menu. 6. Select the module you wish to program. 7. Select "Normal" for Programming Type. 8. Select the applicable software calibrations. 9. Transfer data file to the scan tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions Brake Switch - TCC: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8516 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8517 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8518 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8519 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8520 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8521 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8522 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8523 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8524 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8525 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8526 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8527 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8528 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8529 Brake Switch - TCC: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8530 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8531 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8532 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8533 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8534 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8535 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8536 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8537 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8538 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8539 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8540 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8541 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8542 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8543 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8544 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8545 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8546 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8547 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8548 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8549 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8550 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8551 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8552 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8553 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8554 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8555 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8556 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8557 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8558 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8559 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8560 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8561 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8562 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8563 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 8564 Power, Ground and Brake Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Component Locations Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Component Locations > Page 8569 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 8570 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 8571 Fluid Pressure Sensor/Switch: Service and Repair Pressure Switch Manifold Replacement Removal Procedure 1. Important: Individual pressure switches cannot be replaced. When any pressure switch needs replacing, the entire assembly must be replaced. Important: The G solenoid has been removed for clarity. Remove the oil pan and suction filter. 2. Remove the two bolts (2). Remove the reverse signal tube (1). 3. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the internal wiring harness connector from the pressure switch assembly (2). 4. Remove five bolts (1). Remove the pressure switch assembly (2). Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 8572 1. Notice: Refer to Fastener Notice in Service Precautions. Place the new pressure switch manifold assembly (2) in position and install one bolt (1) in a recessed location to hold it into position. Start the remaining four bolts (1) in recessed locations and tighten the bolts by hand. Torque the bolts to 12 Nm (108 inch lbs.). 2. Connect the internal wiring harness connector to the pressure switch assembly. 3. Install the reverse signal tube (1). Install two bolts (2). ^ Tighten the bolts to 12 Nm (108 inch lbs.). 4. Install the oil pan and suction filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch: Testing and Inspection 4L60/4L60-E/4L65-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit tests are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 8577 Steps 1-9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 8578 Tow/Haul Switch: Testing and Inspection 4L80-E/4L85-E Transmission Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between up shifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Diagnostic Aids If the electrical circuit checks are OK and the tow/haul shift pattern is not occurring, there may be a mechanical/hydraulic condition that prevents tow/haul operation. Refer to Symptoms - Automatic Transmission. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Tow/Haul Switch <--> [Transmission Mode Switch, A/T] > Component Information > Testing and Inspection > 4L60/4L60-E/4L65-E Transmission > Page 8579 Steps 1-9 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. 6. This step tests for ground integrity. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start Transmission Position Switch/Sensor: Customer Interest A/T - Slow/No Gear Engagement/Engine No Start Bulletin No.: 02-07-30-011C Date: June 21, 2004 TECHNICAL Subject: Slow or No Engagement of Automatic Transmission, No Start, Blank PRNDL Display, Flashing PRNDL, DTC P0708, P0872, P0847, P0875, P1711, P1713 or U1000 Set (Diagnose Condition, Repair According to Procedure) Models: 2001-2004 Chevrolet Silverado 2001-2004 GMC Sierra with Allison(R) LCT1000 Automatic Transmission (RPO M74) and 6.6L Duramax(TM) Diesel Engine (RPO LB7) or 8.1L Gas Engine (RPO L18) Supercede: This bulletin is being revised to add model years and additional model information and add graphics. Please discard Corporate Bulletin Number 02-07-30-011B (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions. ^ The PRNDL display is flashing. ^ The engine will not start. ^ The "Service Engine Soon" Indicator lamp is illuminated. ^ The transmission does not shift properly. ^ The vehicle will not move, transmission will not engage. Cause Moisture contamination within the Park Neutral Position (PNP) Switch may cause this condition. This is sometimes referred to as the Neutral Start Back-up (NSBU) Switch. On a left turn, water spray from the left front tire is directed directly at this switch. Proper installation of the "Front Shield" and "Rear Shield" are essential for proper repairs. Technician Diagnosis This bulletin ONLY applies to vehicles equipped with a two connector PNP switch as shown above. A complete and through diagnosis must be performed by a qualified electrical technician to determine the cause and avoid needless replacement of good components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 8588 Important: The Transmission Control Module (TCM) and or the Pressure Switch Manifold (PSM) should NOT be replaced unless properly diagnosed. They are probably not the cause of the concern. It is often assumed the module is the cause of the concern when, in fact, it is another component or the wiring between the components that causes the concern. Important: Remember, everything starts with a properly operating Neutral Start Back Up (NSBU) switch. The NSBU switch has been incorporated into what is now called the Park Neutral Position (PNP) switch. If the PNP switch does not provide the proper voltage signal to the module indicating the transmission is in either Park or Neutral, the module will not allow the starter operation. After the engine is started, and the shift lever is moved to either Reverse or one of the drive positions, the range selected portion of the PNP switch portion provides a voltage input to the module as to what range the driver has manually selected for transmission operation. The module then controls pressures, shift points and other transmission functions based on the voltage input received from the range portion of the PNP switch. The technician may find one or more of the following conditions. The list of these conditions does not imply any type of frequency or order. They are random events and may occur in any order. ^ DTC P0708, Neutral start/backup (PNP or NSBU) switch ^ DTC P0847, Pressure Switch Manifold (PSM) ^ DTC P0872, Pressure Switch Manifold (PSM) ^ DTC P0875, Pressure Switch Manifold (PSM) ^ DTC P1711, Pressure Switch Manifold (PSM) ^ DTC P1713, Pressure Switch Manifold (PSM) ^ DTC U1000, Serial Data Communications ^ Blank PRNDL Display ^ Flashing PRNDL Display ^ Slow or No Engagement of Automatic Transmission Blank PRNDL Display A blank PRNDL display may indicate a condition with the PNP switch and/or one or more of the four signal circuits from the PNP to the TCM. 1. Pin A, Circuit 771 (BLK/WHT) 2. Pin B, Circuit 773 (GRA) 3. Pin C, Circuit 776 (WHT) 4. Pin D, Circuit 772 (YEL) Or, a blank PRNDL display may also occur if an out of line condition exists with the Serial Data Circuit (CKT 2470, yellow wire) from the TCM to Splice Pack 205. Diagnostic Tip 1. Connect the Tech 2(R) to the vehicle. 2. Power up the Tech 2(R). 3. Does the Tech 2(R) communicate with the TCM? If not, inspect the serial data circuit, CKT 2470 (Yellow wire), between the TCM and Splice Pack 205. Specifically inspect connector C106, a five terminal connector located below the left side underhood bussed electrical center, directly beneath the red battery cable terminal connection. Perform a mating terminal pull test on all of the terminals in this connector. Repair as required. 4. Observe the Gear Selected screen on the scan tool. The following values should be shown on the Tech 2(R) display and the vehicle's instrument panel cluster (if equipped with the I/P display). ^ "8" (shifter should be in the Park position) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 8589 ^ "7" (shifter should be in the Reverse position) ^ "5" (shifter should be in the Drive position) ^ "3" (shifter should be in the Third gear position) ^ "2" (shifter should be in the Second gear position) ^ "1" (shifter should be in the First gear position) ^ "0" (shifter should be in the Neutral Position) If the Gear Selected display does not match the shifter position in the vehicle, diagnose using one of the following methods. ^ Obtain a new PNP switch kit, P/N 29540479, from the Parts Department. ^ 0.1. Disconnect the wiring connector from the original transmission mounted PNP switch. ^ 0.2. Connect the new switch to the wiring connector. ^ 0.3. Return to Step # 4 above and observe the display as you rotate the switch. If all positions indicate properly, refer to the Correction section below. ^ Use the DTC P0708 diagnostic chart in Service Information (SI) under Transmission/Transaxle/Automatic Transmission - Allison. Reference SI Document ID # 769549 for the wiring schematic for this symptom. The PNP switch, as referenced in SI, is known as the NSBU switch in the Parts information. It is now serviced with a Park Neutral Position Switch Kit, P/N 29540479. Flashing PRNDL Display A flashing PRNDL display may be the result of incorrect sensor inputs or transmission abuse protection modes being received by the TCM. The following are some of these conditions: ^ The transfer case is/was in Neutral. ^ The transfer case is/was shifted into Neutral when the vehicle is moving. ^ A decrease of the input turbine speed was not detected when the gear selector was moved into any gear. ^ A low transmission fluid level. ^ A misadjusted PNP/NSBU switch. ^ Turbine input speed or output speed sensor failure. ^ Failures of the shift solenoids to route the transmission oil to the proper clutch assemblies within the transmission. ^ Failures of the transmission clutch packs (C1 or C5 for first gear, C3 or C5 for Reverse). ^ Failure to detect proper line pressures when a gear range is selected, which may be the result of normal maintenance such as a transmission fluid change having been completed, or the transmission pan was removed for a filter replacement or other type service. Transmission abuse protection modes are encountered when a customer performs one of the following types of maneuvers: ^ Shifting from Neutral to Drive/Reverse when the engine RPM is greater than 1400 RPM. ^ Shifting from Drive to Reverse when the throttle position (TPS) is greater than 25%, such as rocking the vehicle when stuck in an attempt to free the vehicle. ^ When the transmission output speed is greater than 300 RPM from attempted changes in direction such as Reverse to Drive, Drive to Reverse or Neutral to Reverse shifts. When the TCM encounters any one of the above conditions, the TCM will flash the PRNDL and default the transmission to Neutral. A flashing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 8590 PRNDL indicates something is/was incorrect. The transmission may need the attention of a qualified service technician. Correction 1. Disconnect the wiring harness from the PNP switch. 2. Disconnect the shift linkage/cable from the shift lever at the transmission. 3. With a wrench keeping the shift lever from rotating, remove the nut from the end of the selector shaft. 4. Use a file to remove any burrs or raised metal where the selector lever was seated against the shoulder of the selector shaft. Important: If the old PNP switch will not slide from the selector shaft without the effort, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 5. Remove the two bolts that attach the PNP switch and remove the switch by sliding it outward over the selector shaft. 6. Make sure the selector shaft is in the N (neutral) position (using a wrench on the selector shaft flats, rotate the shaft to its furthest clockwise position and then rotate counterclockwise two detents). Important: If the new PNP switch will not slide onto the selector shaft easily, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 7. Slide the new PNP switch over the selector shaft with the neutral assurance bracket 920 facing outward and maintaining the correct PNP switch orientation to the selector shaft. Install and hand tighten the two PNP switch attaching bolts so that the PNP switch and bracket may be rotated within the adjusting slots with some effort. 8. While holding the neutral assurance bracket in engagement with the PNP switch, tighten the two bolts that attach the PNP switch to the transmission case. Tighten Tighten the bolts to 27 N.m (20 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 8591 9. Remove and discard the neutral assurance bracket. Important: Installation of the front shield and rear shields are important. Without proper installation of the shield, a return repair is probable. Follow all directions as listed on the installation instructions sheet included in the Switch kit, P/N 29540479. 10. Fit the new shield onto the PNP switch so that it fits securely against the switch. Make sure this is done before reinstalling the shift lever. 11. Reinstall the shift lever. With a wrench keeping the shift lever from rotating, install the nut on the end of the selector shaft. Tighten. Tighten the nut to 24 N.m (18 lb ft). 12. Connect the wiring harness connectors to the PNP switch. 13. Attach the selector cable to the lever. Check and adjust if needed. 14. Go back to step 4 of the Diagnostics and insure the Tech 2 readings match the shift lever positions. Important: Clear all DTCs before returning the vehicle to the customer. 15. Return the vehicle to the customer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 8592 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Slow/No Gear Engagement/Engine No Start Bulletin No.: 02-07-30-011C Date: June 21, 2004 TECHNICAL Subject: Slow or No Engagement of Automatic Transmission, No Start, Blank PRNDL Display, Flashing PRNDL, DTC P0708, P0872, P0847, P0875, P1711, P1713 or U1000 Set (Diagnose Condition, Repair According to Procedure) Models: 2001-2004 Chevrolet Silverado 2001-2004 GMC Sierra with Allison(R) LCT1000 Automatic Transmission (RPO M74) and 6.6L Duramax(TM) Diesel Engine (RPO LB7) or 8.1L Gas Engine (RPO L18) Supercede: This bulletin is being revised to add model years and additional model information and add graphics. Please discard Corporate Bulletin Number 02-07-30-011B (Section 07 Transmission/Transaxle). Condition Some customers may comment on one or more of the following conditions. ^ The PRNDL display is flashing. ^ The engine will not start. ^ The "Service Engine Soon" Indicator lamp is illuminated. ^ The transmission does not shift properly. ^ The vehicle will not move, transmission will not engage. Cause Moisture contamination within the Park Neutral Position (PNP) Switch may cause this condition. This is sometimes referred to as the Neutral Start Back-up (NSBU) Switch. On a left turn, water spray from the left front tire is directed directly at this switch. Proper installation of the "Front Shield" and "Rear Shield" are essential for proper repairs. Technician Diagnosis This bulletin ONLY applies to vehicles equipped with a two connector PNP switch as shown above. A complete and through diagnosis must be performed by a qualified electrical technician to determine the cause and avoid needless replacement of good components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 8598 Important: The Transmission Control Module (TCM) and or the Pressure Switch Manifold (PSM) should NOT be replaced unless properly diagnosed. They are probably not the cause of the concern. It is often assumed the module is the cause of the concern when, in fact, it is another component or the wiring between the components that causes the concern. Important: Remember, everything starts with a properly operating Neutral Start Back Up (NSBU) switch. The NSBU switch has been incorporated into what is now called the Park Neutral Position (PNP) switch. If the PNP switch does not provide the proper voltage signal to the module indicating the transmission is in either Park or Neutral, the module will not allow the starter operation. After the engine is started, and the shift lever is moved to either Reverse or one of the drive positions, the range selected portion of the PNP switch portion provides a voltage input to the module as to what range the driver has manually selected for transmission operation. The module then controls pressures, shift points and other transmission functions based on the voltage input received from the range portion of the PNP switch. The technician may find one or more of the following conditions. The list of these conditions does not imply any type of frequency or order. They are random events and may occur in any order. ^ DTC P0708, Neutral start/backup (PNP or NSBU) switch ^ DTC P0847, Pressure Switch Manifold (PSM) ^ DTC P0872, Pressure Switch Manifold (PSM) ^ DTC P0875, Pressure Switch Manifold (PSM) ^ DTC P1711, Pressure Switch Manifold (PSM) ^ DTC P1713, Pressure Switch Manifold (PSM) ^ DTC U1000, Serial Data Communications ^ Blank PRNDL Display ^ Flashing PRNDL Display ^ Slow or No Engagement of Automatic Transmission Blank PRNDL Display A blank PRNDL display may indicate a condition with the PNP switch and/or one or more of the four signal circuits from the PNP to the TCM. 1. Pin A, Circuit 771 (BLK/WHT) 2. Pin B, Circuit 773 (GRA) 3. Pin C, Circuit 776 (WHT) 4. Pin D, Circuit 772 (YEL) Or, a blank PRNDL display may also occur if an out of line condition exists with the Serial Data Circuit (CKT 2470, yellow wire) from the TCM to Splice Pack 205. Diagnostic Tip 1. Connect the Tech 2(R) to the vehicle. 2. Power up the Tech 2(R). 3. Does the Tech 2(R) communicate with the TCM? If not, inspect the serial data circuit, CKT 2470 (Yellow wire), between the TCM and Splice Pack 205. Specifically inspect connector C106, a five terminal connector located below the left side underhood bussed electrical center, directly beneath the red battery cable terminal connection. Perform a mating terminal pull test on all of the terminals in this connector. Repair as required. 4. Observe the Gear Selected screen on the scan tool. The following values should be shown on the Tech 2(R) display and the vehicle's instrument panel cluster (if equipped with the I/P display). ^ "8" (shifter should be in the Park position) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 8599 ^ "7" (shifter should be in the Reverse position) ^ "5" (shifter should be in the Drive position) ^ "3" (shifter should be in the Third gear position) ^ "2" (shifter should be in the Second gear position) ^ "1" (shifter should be in the First gear position) ^ "0" (shifter should be in the Neutral Position) If the Gear Selected display does not match the shifter position in the vehicle, diagnose using one of the following methods. ^ Obtain a new PNP switch kit, P/N 29540479, from the Parts Department. ^ 0.1. Disconnect the wiring connector from the original transmission mounted PNP switch. ^ 0.2. Connect the new switch to the wiring connector. ^ 0.3. Return to Step # 4 above and observe the display as you rotate the switch. If all positions indicate properly, refer to the Correction section below. ^ Use the DTC P0708 diagnostic chart in Service Information (SI) under Transmission/Transaxle/Automatic Transmission - Allison. Reference SI Document ID # 769549 for the wiring schematic for this symptom. The PNP switch, as referenced in SI, is known as the NSBU switch in the Parts information. It is now serviced with a Park Neutral Position Switch Kit, P/N 29540479. Flashing PRNDL Display A flashing PRNDL display may be the result of incorrect sensor inputs or transmission abuse protection modes being received by the TCM. The following are some of these conditions: ^ The transfer case is/was in Neutral. ^ The transfer case is/was shifted into Neutral when the vehicle is moving. ^ A decrease of the input turbine speed was not detected when the gear selector was moved into any gear. ^ A low transmission fluid level. ^ A misadjusted PNP/NSBU switch. ^ Turbine input speed or output speed sensor failure. ^ Failures of the shift solenoids to route the transmission oil to the proper clutch assemblies within the transmission. ^ Failures of the transmission clutch packs (C1 or C5 for first gear, C3 or C5 for Reverse). ^ Failure to detect proper line pressures when a gear range is selected, which may be the result of normal maintenance such as a transmission fluid change having been completed, or the transmission pan was removed for a filter replacement or other type service. Transmission abuse protection modes are encountered when a customer performs one of the following types of maneuvers: ^ Shifting from Neutral to Drive/Reverse when the engine RPM is greater than 1400 RPM. ^ Shifting from Drive to Reverse when the throttle position (TPS) is greater than 25%, such as rocking the vehicle when stuck in an attempt to free the vehicle. ^ When the transmission output speed is greater than 300 RPM from attempted changes in direction such as Reverse to Drive, Drive to Reverse or Neutral to Reverse shifts. When the TCM encounters any one of the above conditions, the TCM will flash the PRNDL and default the transmission to Neutral. A flashing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 8600 PRNDL indicates something is/was incorrect. The transmission may need the attention of a qualified service technician. Correction 1. Disconnect the wiring harness from the PNP switch. 2. Disconnect the shift linkage/cable from the shift lever at the transmission. 3. With a wrench keeping the shift lever from rotating, remove the nut from the end of the selector shaft. 4. Use a file to remove any burrs or raised metal where the selector lever was seated against the shoulder of the selector shaft. Important: If the old PNP switch will not slide from the selector shaft without the effort, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 5. Remove the two bolts that attach the PNP switch and remove the switch by sliding it outward over the selector shaft. 6. Make sure the selector shaft is in the N (neutral) position (using a wrench on the selector shaft flats, rotate the shaft to its furthest clockwise position and then rotate counterclockwise two detents). Important: If the new PNP switch will not slide onto the selector shaft easily, the selector shaft may need to be filed to remove flaring on the end of the selector shaft. This is important, installing the new switch onto a selector shaft that has damage will cause damage to the new PNP switch. 7. Slide the new PNP switch over the selector shaft with the neutral assurance bracket 920 facing outward and maintaining the correct PNP switch orientation to the selector shaft. Install and hand tighten the two PNP switch attaching bolts so that the PNP switch and bracket may be rotated within the adjusting slots with some effort. 8. While holding the neutral assurance bracket in engagement with the PNP switch, tighten the two bolts that attach the PNP switch to the transmission case. Tighten Tighten the bolts to 27 N.m (20 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 8601 9. Remove and discard the neutral assurance bracket. Important: Installation of the front shield and rear shields are important. Without proper installation of the shield, a return repair is probable. Follow all directions as listed on the installation instructions sheet included in the Switch kit, P/N 29540479. 10. Fit the new shield onto the PNP switch so that it fits securely against the switch. Make sure this is done before reinstalling the shift lever. 11. Reinstall the shift lever. With a wrench keeping the shift lever from rotating, install the nut on the end of the selector shaft. Tighten. Tighten the nut to 24 N.m (18 lb ft). 12. Connect the wiring harness connectors to the PNP switch. 13. Attach the selector cable to the lever. Check and adjust if needed. 14. Go back to step 4 of the Diagnostics and insure the Tech 2 readings match the shift lever positions. Important: Clear all DTCs before returning the vehicle to the customer. 15. Return the vehicle to the customer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-011C > Jun > 04 > A/T - Slow/No Gear Engagement/Engine No Start > Page 8602 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 03-01-38-015A > Oct > 08 > A/C - Blower Motor Runs After Vehicle Is Shut OFF Blower Motor Relay: All Technical Service Bulletins A/C - Blower Motor Runs After Vehicle Is Shut OFF TECHNICAL Bulletin No.: 03-01-38-015A Date: October 27, 2008 Subject: HVAC Blower Motor May Run Continuously After Vehicle is Turned Off (Replace Blower Resistor Relay) Models: 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2004 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon XL with Manual Control HVAC (RPO CJ3) Built Prior to August, 2003 Supercede: This bulletin is being revised to update the parts information. Please discard Corporate Bulletin Number 03-01-38-015 (Section 01 - HVAC). Condition Some customers may comment on the HVAC blower motor running after the vehicle has been turned off. The blower may run for just a few minutes or continuously until the battery is discharged. Cause A new style HVAC blower relay/resistor may stick in the "on" position. When the HVAC fan blower relay has been energized, the contacts may "micro-weld" together. After this occurrence, the HVAC blower may not respond to the HVAC controller commands. Correction Replace the HVAC blower resistor/relay with the type used previous to the 2004 model year. The appropriate part numbers are listed in the table below. For specific repair procedures, refer to the 2004 Service Information (SI) under Blower Motor Resistor Assembly Replacement (SI Document ID # 526350 (C/K) or # 729996 (S/T). Parts Information Warranty Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 8613 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 8614 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E Transmission Position Switch/Sensor: Adjustments Automatic Transmission - 4L80-E/4L85-E Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the park brake. ^ The engine must start in the park (P) or neutral (N) positions only. ^ Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the shift lever in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the PNP switch bolts. 4. With the vehicle in neutral (N), rotate the PNP switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. 6. Notice: Refer to Fastener Notice in Service Precautions. Tighten the PNP switch bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 8617 Transmission Position Switch/Sensor: Adjustments Automatic Transmission - Allison Park/Neutral Position Switch Adjustment ^ Tools Required J 41364-A PNP Switch Adjusting Tool Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Make sure the selector shaft is in the N (Neutral) position as follows: ^ Place a wrench on the selector shaft flats and rotate the shaft to its furthest clockwise position. ^ Rotate the selector shaft counter-clockwise two detents. 2. Be sure that J 41364-A (2) is in the proper position on PNP switch (1). 3. While maintaining the correct PNP switch-to-selector-shaft alignment, slide the new PNP switch (5) over the selector shaft (4). 4. Notice: Refer to Component Fastener Tightening Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Adjustments > Automatic Transmission - 4L80-E/4L85-E > Page 8618 While holding J 41364-A in engagement with the PNP switch, install the two bolts (6) so that the PNP switch may be rotated with some effort. ^ Tighten the two bolts (6) to 27 Nm (20 ft. lbs.). 5. Remove J 41364-A. 6. Install splash shield (1), concave side toward PNP switch (3), over selector shaft (2). 7. Notice: Refer to Transmission Selector Shaft Abuse Notice in Service Precautions. Reinstall Shift Lever (2). Install nut (3), by hand, on the end of selector shaft (4). Use a wrench (1) to keep the shift lever from rotating. ^ Tighten nut (3) to 24 Nm (18 ft. lbs.) 8. Reconnect the shift selector linkage/cable to the shift lever (2). 9. Connect the external wiring harness to the PNP switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E Transmission Position Switch/Sensor: Service and Repair Automatic Transmission 4L80-E/4L85-E Park/Neutral Position Switch Replacement Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the range selector cable end (2) from the range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 8621 7. Remove the control lever to the manual shaft nut. 8. Remove the control lever from the manual shaft. 9. Remove the PNP switch bolts. 10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. 3. Important: If a new PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. Install the PNP switch bolts finger tight. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 8622 4. Position the J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. 5. Notice: Refer to Fastener Notice in Service Precautions. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the control lever to the manual shaft with the nut. 8. Install the manual shaft nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 9. Install the range selector cable end (2) to the range selector lever ball stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 8623 10. Connect the PNP switch electrical connector (2). 11. If equipped with 4WD, install the front propeller shaft. 12. Lower the vehicle. 13. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Park Lock Pawl and Actuator Replacement Park Lock Pawl and Actuator Replacement Removal Procedure 1. Remove the transmission filter. 2. Remove the park/neutral position (PNP) switch. 3. Remove the manual shaft nut and pin. 4. Remove the detent lever and actuator. 5. Remove the parking pawl bracket bolts. 6. Remove the parking pawl return spring. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 8624 7. Use the modified screw extractor in order to remove the plug. 8. Remove the parking pawl shaft retainer, shaft and pawl. 9. Important: If the manual shaft binds in the case during removal, file or sand the shaft in the area adjacent to the detent lever. Remove the manual shaft. 10. Remove the manual shaft seal. Installation Procedure 1. Install the pawl shaft. 2. Install the parking pawl. 3. Install the plug using a 8 mm or (5/16 inch) rod with Loctite® or equivalent. 4. Install the retainer. 5. Install the pawl return spring. 6. Install the detent lever to the actuator. 7. Install the actuator over the parking pawl. 8. Install the manual shaft seal. 9. Lubricate the manual shaft with transmission oil and install the manual shaft into the case. 10. Install the nut on the shaft. 11. Install the roll pin. 12. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 8625 Install the parking lock bracket bolts. ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 13. Install the PNP switch. 14. Install the transmission filter. 15. Fill the transmission to the proper level with Dexron® III transmission fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 8626 Transmission Position Switch/Sensor: Service and Repair Automatic Transmission - Allison Park/Neutral Position Switch Replacement PNP Switch Removal Refer to Park/Neutral Position Switch Removal. PNP Switch Install Refer to Park/Neutral Position Switch Installation. 7. Notice: Refer to Transmission Selector Shaft Abuse Notice in Service Precautions. Reinstall shift lever (2). Install nut (3), by hand, on the end of selector shaft (4). Use a wrench (1) to keep the shift lever from rotating. ^ Tighten nut (3) to 24 Nm (18 ft. lbs.). 8. Reconnect the shift selector linkage/cable to the shift lever (2). 9. Connect the external wiring harness to the PNP switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Electrical Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Electrical Specifications > Page 8631 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 8632 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E Transmission Speed Sensor: Diagrams Automatic Transmission - 4L80-E/4L85-E Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 8635 Transmission Speed Sensor: Diagrams Automatic Transmission - Allison Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Automatic Transmission - 4L80-E/4L85-E > Page 8636 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E Transmission Speed Sensor: Service and Repair Automatic Transmission - 4L80-E/4L85-E Input Shaft Speed Sensor Replacement Input Shaft Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt. 4. Remove the input speed sensor (1). 5. Inspect the input speed sensor (1) for any evidence of damage. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 8639 1. Lubricate the input speed sensor seal with automatic transmission fluid. 2. Install the input speed sensor (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the input speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). 4. Connect the input speed sensor electrical connector (1). 5. Lower the vehicle. Output Shaft Speed Sensor Replacement Output Shaft Speed Sensor Replacement Removal Procedure Important: This procedure is for 2-wheel drive (2WD) vehicles only. If the vehicle is equipped with 4-wheel drive (4WD), the output speed sensor is located on the transfer case. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 8640 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the output speed sensor (2) electrical connector. 3. Remove the output speed sensor bolt. 4. Remove the output speed sensor (2). 5. Inspect the output speed sensor (2) for any evidence of damage. Installation Procedure 1. Lubricate the output speed sensor seal with automatic transmission fluid. 2. Install the output speed sensor (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the output speed sensor bolt. ^ Tighten the bolt to 11 Nm (96 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 8641 4. Connect the output speed sensor (2) electrical connector. 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 8642 Transmission Speed Sensor: Service and Repair Automatic Transmission - Allison Speed Sensor Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Be sure the vehicle ignition is turned off. 2. Disconnect the external wiring harness from the speed sensor. 3. Remove the bolt (1) from the speed sensor and carefully remove the speed sensor (2). Installation Procedure 1. Important: Do not rotate the sensor in its retaining bracket. Changing the sensor/bracket orientation may cause improper operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Automatic Transmission - 4L80-E/4L85-E > Page 8643 Install a new a O-ring (3) on the speed sensor (2). Lubricate the O-ring with clean transmission fluid. 2. Install the new speed sensor (2) into the speed sensor bore. Align the hole in the retaining bracket with the bolt hole in the speed sensor boss. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor bolt (1). ^ Tighten bolt (1) to 12 Nm (108 inch lbs.). 4. Reconnect the external wiring harness to the speed sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Electrical Specifications Transmission Temperature Sensor/Switch: Electrical Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Electrical Specifications > Page 8648 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Electrical Specifications > Page 8649 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Component Locations Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Component Locations > Page 8652 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Remote Control: Description and Operation Steering Wheel Controls STEERING WHEEL CONTROLS Some audio functions are available using the steering wheel controls. The steering wheel controls consist of multiple momentary contact switches that connect a series of resistors. When a steering wheel control button is pressed, a specific resistance value is noted by the body control module (BCM). This results in a generated voltage, unique to the particular button. The BCM alerts the radio that the button has been pressed, and the radio responds, just as if the corresponding radio front panel button had been pressed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8657 Remote Control: Testing and Inspection For Steering Wheel Controls Testing information refer to Radio, Stereo and Compact Disc, See: Testing and Inspection Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Transfer Case - NVG 246-NP8 Front Door Exterior Handle: Service and Repair Door Handle Replacement - Outside Removal Procedure 1. Remove the trim panel. 2. Remove the water deflector.\ 3. Remove the outside handle rod from the rod clip. 4. Remove the lock cylinder rod from the rod clip. 5. Apply masking tape across the door handle on the outside of the door to secure handle while removing the nuts. 6. Remove the outside handle mounting nuts. 7. Remove the rubber cover in order to gain access to the outboard nut. 8. Remove the door lock cylinder from the outside handle housing. In order to repair a binding lock cylinder, refer to Binding Lock Cylinders. 9. Remove the handle. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Transfer Case - NVG 246-NP8 > Page 8660 1. Install the handle to the vehicle. 2. If the lock cylinder is a replacement, apply a coating of GM P/N 12345120 or Canadian P/N 726548 or a similar lubricant to the inside of the lock case and the cylinder keyway. 3. Install the door lock cylinder to the outside handle housing. In order to code a new lock cylinder. 4. Install the lock cylinder clip to the lock cylinder rod. 5. Install the handle rod to the handle assembly clip. 6. Remove masking tape from door handle. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the outside handle mounting nuts. Tighten the nuts to 9 N.m (80 lb in). 8. Install the rubber cover. 9. Install the water deflector. 10. Install the trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > Transfer Case - NVG 246-NP8 > Page 8661 Instrument Panel Switches-LH Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair Gear Sensor/Switch: Service and Repair Encoder Motor Sensor Replacement Removal Procedure Important: For ease of reassembly, shift the transfer case to 2HI prior to removing any components. 1. Remove the encoder motor. 2. Place the encoder motor on a clean work bench, 3. Remove the 2 screws (2) from the motor cover. 4. Remove the 2 screws (1) from the casting. 5. Remove the cover. 6. Remove and save the shim on the output gear. 7. Remove and discard the orange rubber seal from the cover. 8. Remove the output gear (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Page 8665 9. Disassemble the harness connector (1) from the encoder. 10. Remove the encoder from the output shaft using a flat tip screwdriver. Installation Procedure 1. Assemble the harness to the NEW encoder with the connector legend "TOP" (1) and the encoder part number facing up. 2. Assemble the output shaft into the encoder, being sure to align the encoder tab with the groove on the shaft. 3. Ensure the encoder is seating properly on the output gear. 4. Place the output shaft encoder on the casting. 5. Place the grommet harness on the casting slot, the flat area on the grommet will be facing up. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Page 8666 6. With the output gear encoder assembly in hand, carefully align the casting and output gear timing marks (1). 7. At the same time, be sure to align the encoder phasing post (1) with the phasing slot (2) in the casting and insert the shaft into the bushing. 8. Verify that the output gear and idler are engaged properly. 9. Seat the harness wires on the casting channel. 10. Place the shim on the output shaft gear. 11. Press a NEW seal into the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Page 8667 12. Install the cover. Notice: Refer to Fastener Notice in Service Precautions. 13. Install 2 NEW screws (1) to the casting. ^ Tighten the screws to 2 Nm (18 inch lbs.). 14. Install 2 NEW longer screws (2) to the motor cover. ^ Tighten the screws to 3 Nm (26 inch lbs.). 15. Install the encoder motor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: Customer Interest Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set > Page 8676 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set Speed Sensor: All Technical Service Bulletins Drivetrain - Service 4WD Light/DTC C0374 Set TECHNICAL Bulletin No.: 05-04-21-003C Date: April 15, 2008 Subject: Service 4WD Light Illuminated, DTC C0374 Set (Inspect Wiring Harness to Transfer Case Speed Sensors,, Replace Wiring Harness) Models: 2004-2007 Buick Rainier 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado Classic, TrailBlazer, TrailBlazer EXT 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Envoy, Envoy XL, Sierra Classic 2003-2004 Oldsmobile Bravada 2005-2007 Saab 9-7X With Four Wheel Drive or All-Wheel Drive and Active All-Wheel Drive (RPO NP4) or Active Two-Speed (RPO NP8) Transfer Case Supercede: This bulletin is being revised to update the Model and Warranty Information. Please discard Corporate Bulletin Number 05-04-21-003B (Section 04 - Driveline/Axle). Condition Some customers may comment on intermittent illumination of the Service 4WD light. Upon investigation, the technician may find DTC C0374 set. The customer may also comment on intermittent erratic operation of the 4WD or AWD system after driving through rain/snow or simply going through a car wash. Cause The speed sensor signal may have become corrupted. Possible openings in the speed sensor wire insulation (twisted pairs) can allow water intrusion. Also wire connections contaminated by water may result in short circuits and erroneous speed sensor readings. This most often occurs on the rear speed sensor circuit. Correction Inspect the wiring harness to the transfer case speed sensors. On Rainier, TrailBlazer, Envoy and 9-7X models, fabricate a replacement speed sensor harness between the C101 connector and the speed sensors. Completely inspect and test all wiring. Refer to Speed Signal Front Axle Actuator and Indicators schematic in SI. Replace the affected twisted pairs. Do not over-twist the two wires in the replacement harness. Wires should be twisted at a rate of 9 revolutions per foot. Use service connector pack, P/N 88987993 at the speed sensor end and terminal, P/N 15326267, at C101. Terminal testing tools and service terminals can be found in Terminal Repair Kit J 38125. Terminals are available from SPX/Kent-Moore. The smaller transfer case harness splices into the larger chassis harness a few inches in front of the crossmember. The chassis harness routes along the left side of the frame under the driver door area. Use nylon tie straps to secure the fabricated harness to the main chassis harness between the transfer case and C101. On the full-size pickup and full-size utility models, replace the 2.2 m (88 in) pigtail harness that runs from the C151 connector under the hood to the transfer case. Use either harness P/N 15832722 or 15224663 depending on vehicle equipment. Refer to Propshaft Speed Sensors Front Axle Actuator and Transfer Case Shift Control Switch schematic in SI. Important: Technicians should verify the integrity of the splice joints after the repair. All splice joints and connections should seal properly against water or a repeat condition can occur. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 05-04-21-003C > Apr > 08 > Drivetrain - Service 4WD Light/DTC C0374 Set > Page 8682 Parts Information Warranty Information (excluding Saab U.S. Models) Warranty Information (Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 06-04-21-001 > May > 06 > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speed Sensor: > 06-04-21-001 > May > 06 > Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: All Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Propshaft Speed Sensor - Front > Page 8694 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 Speed Sensor: Service and Repair Transfer Case - NVG 149-NP3 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8697 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8698 Speed Sensor: Service and Repair Transfer Case - NVG 246-NP8 Transfer Case Speed Sensor Replacement - Front Transfer Case Speed Sensor Replacement - Front Removal Procedure 1. Remove the transfer case shield, if equipped. 2. Disconnect the front speed sensor electrical connector (5). 3. Remove the front speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the front speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8699 2. Connect the front speed sensor electrical connector (5). 3. Install the transfer case shield, if equipped. Transfer Case Speed Sensor Replacement - Left Rear Transfer Case Speed Sensor Replacement - Left Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the left rear speed sensor electrical connector (4). 3. Remove the left rear speed sensor. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8700 1. Notice: Refer to Fastener Notice in Service Precautions. Install the left rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the left rear speed sensor electrical connector (4) 3. Lower the vehicle. Transfer Case Speed Sensor Replacement - Right Rear Transfer Case Speed Sensor Replacement - Right Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the right rear speed sensor electrical connector (3). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8701 3. Remove the right rear speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the right rear speed sensor. ^ Tighten the speed sensor to 15 Nm (11 ft. lbs.). 2. Connect the right rear speed sensor electrical connector (3). 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8702 Speed Sensor: Service and Repair Transfer Case - NVG 261-NP2 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8703 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8704 Speed Sensor: Service and Repair Transfer Case - NVG 263-NP1 Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the speed sensor electrical connector. 3. Remove the speed sensor. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the speed sensor. ^ Tighten the sensor to 15 Nm (11 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Transfer Case - NVG 149-NP3 > Page 8705 2. Connect the speed sensor electrical connector. 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 8716 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 04-05-25-005A > Sep > 04 > Brakes - ABS Lamp/Service Brake System Message ON Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp/Service Brake System Message ON Bulletin No.: 04-05-25-005A Date: September 28, 2004 ADVANCE SERVICE INFORMATION RESOLUTION Subject: Antilock Brake System (ABS) Light On, Service Brake System Message on Driver Information Center (DIC) (Reprogram Electronic Brake Control Module (EBCM)) Models: 2003-2005 Chevrolet Silverado 2500/3500 HD Series Pickups 2003-2005 GMC Sierra 2500/3500 HD Series Pickups with Identification 2-inch Body Raise, HD Model (RPO HVY) Supercede: This bulletin is being revised to add correction information and additional model years. Please discard Advanced Service Information Bulletin Number 04-05-25-005 (Section 05 - Brakes). Condition Some customers may comment that the ABS light, Service Brake System message comes on intermittently during initial start-up. The condition does not cause a DTC to be stored permanently. Cause The cause may be a timing issue related to the cranking/starting of the vehicles. It appears that the condition is more likely to occur on vehicles with diesel engines, though it can occur on vehicles with gasoline engines as well. Correction Reprogram the EBCM with TIS software version 7.5, released July 26, 2004 or newer. Refer to Service Programming System (SPS). Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 04-05-25-005A > Sep > 04 > Brakes - ABS Lamp/Service Brake System Message ON > Page 8721 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 8727 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 04-05-25-005A > Sep > 04 > Brakes - ABS Lamp/Service Brake System Message ON Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp/Service Brake System Message ON Bulletin No.: 04-05-25-005A Date: September 28, 2004 ADVANCE SERVICE INFORMATION RESOLUTION Subject: Antilock Brake System (ABS) Light On, Service Brake System Message on Driver Information Center (DIC) (Reprogram Electronic Brake Control Module (EBCM)) Models: 2003-2005 Chevrolet Silverado 2500/3500 HD Series Pickups 2003-2005 GMC Sierra 2500/3500 HD Series Pickups with Identification 2-inch Body Raise, HD Model (RPO HVY) Supercede: This bulletin is being revised to add correction information and additional model years. Please discard Advanced Service Information Bulletin Number 04-05-25-005 (Section 05 - Brakes). Condition Some customers may comment that the ABS light, Service Brake System message comes on intermittently during initial start-up. The condition does not cause a DTC to be stored permanently. Cause The cause may be a timing issue related to the cranking/starting of the vehicles. It appears that the condition is more likely to occur on vehicles with diesel engines, though it can occur on vehicles with gasoline engines as well. Correction Reprogram the EBCM with TIS software version 7.5, released July 26, 2004 or newer. Refer to Service Programming System (SPS). Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 04-05-25-005A > Sep > 04 > Brakes - ABS Lamp/Service Brake System Message ON > Page 8732 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 8733 Electronic Brake Control Module: Locations ABS Component Views Electronic Brake Control Module (EBCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 8734 Electronic Brake Control Module: Diagrams ABS Connector End Views Electronic Brake Control Module (ECBCM) - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 8735 Electronic Brake Control Module (ECBCM) - C2 (10/20 Series w/o HP2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 8736 Electronic Brake Control Module (ECBCM) - C2 (30 Series and HP2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 8737 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. 3. Important: The area around the EHCU MUST be free from loose dirt to prevent contamination of disassembled ABS components. Thoroughly wash all contaminants from around the EHCU. 4. Disconnect the chassis electrical connectors from the EBCM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 8738 5. Remove the mounting screws (1) that fasten the EBCM (2) to the BPMV (3). 6. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. Notice: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 8739 7. Disconnect the BPMV electrical connector from the EBCM. 8. Clean the BPMV to EBCM mounting surfaces with a clean cloth. Installation Procedure Important: ^ Do not reuse the old mounting screws. Always install new mounting screws with the new EBCM. ^ Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 1. Connect the BPMV electrical connector to the EBCM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 8740 2. Install the EBCM to the BPMV. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the new screws (1) in the EBCM (2). ^ Tighten the screws to 5 Nm (39 inch lbs.) in an X-pattern. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 8741 4. connect the chassis electrical connectors to the EBCM. 5. Lower the vehicle. 6. Connect the negative battery cable. 7. Revise the tire calibration using the Scan Tool Tire Size Calibration function. 8. Return to Diagnostic Starting Point - Antilock Brake System. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Replacement Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Remove the negative battery cable. 2. Important: The area around the EHCU MUST be free from loose dirt to prevent contamination of disassembled ABS components. Thoroughly wash all contaminants from around the EHCU. 3. Disconnect the chassis electrical harness connectors from the EBCM. 4. Important: Make sure that brake lines are tagged and kept in order for proper reassembly. Disconnect 5 brake lines from the BPMV. 5. Remove the bolts (4) securing the EHCU mounting bracket (3) to the frame rail (5). 6. Remove the EHCU assembly (1) from the vehicle. 7. Remove the bolts (4) securing the BPMV mounting bracket (5) to the BPMV (3). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 8745 8. Disconnect the 2 way ABS pump motor connector. 9. Remove the bolts (1) from the EBCM (2). 10. Notice: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. Important: Do not reuse the EBCM mounting bolts. Always install new bolts. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. 11. Clean the EBCM to BPMV mounting surfaces with a clean cloth. Installation Procedure 1. Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. Install the EBCM (2) onto BPMV (3). 2. Important: Do not reuse the old mounting bolts. Always install new bolts with the new BPMV. Install the four EBCM bolts. ^ Tighten the four bolts to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the 2 way ABS pump motor connector to the EBCM. 4. Install the BPMV (3) to BPMV bracket (5). 5. Install the BPMV to bracket retaining bolts (4). ^ Tighten the bolts to 9 Nm (7 ft. lbs.). 6. Install the EHCU assembly (1, 2) to the vehicle frame (5). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 8746 ^ Tighten the three EHCU bracket bolts (4) to 25 Nm (18 ft. lbs.). 7. Connect the chassis electrical harness connectors to the EBCM (1). 8. Important: The brake pipes are held in the proper place by a frame mounted plastic bracket. Make sure that the brake pipes stay in the correct place for proper reassembly. Install the 5 brake pipes to the BPMV (6). ^ Tighten the brake pipe fittings to 25 Nm (18 ft. lbs.). 9. Connect negative battery cable. 10. Bleed the brake system. Refer to ABS Automated Bleed Procedure. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations Traction Control Switch: Locations ABS Component Views Traction Control Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 8750 Traction Control Switch: Diagrams ABS Connector End Views Traction Control Switch (NW7) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 8751 Traction Control Switch: Service and Repair Traction Control Switch Replacement Removal Procedure 1. Remove instrument panel (IP) bezel. 2. Gently lift the switch retaining tabs (1) and remove the traction control switch (2) from the instrument panel (IP) assembly (3). 3. Disconnect the harness connector from the traction control switch. Installation Procedure 1. Connect the harness connector to the traction control switch. 2. Install the traction control switch (2) into the instrument panel (IP) assembly (3), making sure that all of the switch retaining tabs (1) are engaged. 3. Install instrument panel (IP) bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: Customer Interest Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set > Page 8760 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: All Technical Service Bulletins Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set > Page 8766 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05-08-49-018A > May > 06 > Instruments - Service Tire Monitor Message is Displayed Low Tire Pressure Indicator: All Technical Service Bulletins Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 8777 Wheel Speed Sensor: Locations ABS Component Views Wheel Speed Sensor (WSS) - RF and LF Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 8778 Wheel Speed Sensor: Diagrams ABS Connector End Views Wheel Speed Sensor (WSS) - LF Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 8779 Wheel Speed Sensor (WSS) - RF Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 8780 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (4WD) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and wheel. 3. Remove the brake rotor (2) shown on the 1500 series. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the WSS cable mounting clip from the knuckle. 5. Remove the WSS cable mounting clip from the upper control arm. 6. Remove the WSS cable mounting clip from the frame attachment point. 7. Remove the WSS cable electrical connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 8781 8. Remove the wheel speed sensor (WSS) mounting bolt. 9. NOTICE: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. Remove the wheel speed sensor (5) from the hub/bearing assembly (4) shown on the 2500/3500 series. Installation Procedure 1. Plug the WSS bore to prevent debris from falling into the hub. 2. Using a wire brush or equivalent, clean the WSS mounting surface on the hub to remove any rust or corrosion. 3. Apply a thin layer of wheel bearing lubricant, GM P/N 01051344 to the hub surface and the sensor O-ring prior to sensor installation. 4. Install the WSS (5) into the hub/bearing assembly (4) shown on the 2500/3500 series. Ensure that the sensor is seated flat against the hub. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 8782 5. Notice: Refer to Fastener Notice in Service Precautions. Install the WSS mounting bolt. ^ Tighten the WSS mounting bolt to 18 Nm (13 ft. lbs.). 6. Install the WSS cable mounting clip to the knuckle. 7. Install the WSS cable mounting clip to the upper control arm. 8. Install the WSS cable mounting clip to the frame attachment point. 9. Connect the WSS cable electrical connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 8783 10. Install the brake rotor (2) shown on the 1500 series. Refer to Brake Rotor Replacement - Front in Disc Brakes. 11. Install the tire and wheel. 12. Perform the Diagnostic System Check - ABS. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme II Brake Fluid or equivalent DOT-3 brake fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: This procedure may be performed on all vehicles EXCEPT those equipped with option code JL4, Vehicle Stability Enhancement System (VSES). Important: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure) in Hydraulic Brakes before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Depress the brake pedal firmly and maintain steady pressure on the pedal. 4. Using the scan tool, begin the automated bleed procedure. 5. Follow the instructions on the scan tool to complete the automated bleed procedure. Release the brake pedal between each test sequence. 6. Turn the ignition OFF. 7. Remove the scan tool from the vehicle. 8. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11® GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure) in Hydraulic brakes. 10. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 11. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 12. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. Refer to Brake System External Leak Inspection in Hydraulic Brakes. 13. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 14. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes. 15. Drive the vehicle to exceed 13 kph (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 16. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 8789 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition Off and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level.Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 8790 perform the following steps: 1. Inspect the brake system for external leaks. 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 23. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 8791 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) ^ Tools Required J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 35589-A Brake Pressure Bleeder Adapter Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J 35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J 29532 , or equivalent. Add Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J 29532 , or equivalent, to the J 35589-A. 8. Charge the J 29532 , or equivalent, air tank to 175-205 kPa (25-30 psi). 9. Open the J 29532 , or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J 29532 , or equivalent, fluid tank valve, then disconnect the J 29532 , or equivalent, from the J 35589-A. 23. Remove the J 35589-A from the brake master cylinder reservoir. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 8792 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. Refer to ABS Automated Bleed Procedure in Antilock Brake System. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 28. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 8793 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11® (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports.As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair Brake Pedal Assy: Service and Repair Brake Pedal Assembly Replacement Removal Procedure 1. Remove the pushrod retaining clip (4). 2. Remove the stop lamp switch (2) and the pushrod (3) from the brake pedal stud (1). 3. Remove the nut from the brake pedal bolt. 4. Remove the brake pedal bolt. 5. Remove the brake pedal. Installation Procedure 1. Install the brake pedal. 2. Install the brake pedal bolt. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the nut to the brake pedal bolt. Hold the nut with a wrench and tighten the brake pedal bolt to 47 Nm (35 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Page 8797 4. Install the pushrod (3) and the stop lamp switch (2) to the brake pedal pin (1). 5. Install the pushrod retaining clip (4). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up Brake Caliper: Customer Interest Brakes/Wheels - Excessive Debris Build Up Bulletin No.: 04-05-23-005 Date: June 22, 2004 INFORMATION Subject: Availability of Rear Wheel Mud Flaps to Reduce Debris Build-up on Rear Brake Calipers and/or Rear Wheels Models: 1999-2004 Chevrolet Silverado Pickup Models 1999-2004 GMC Sierra Pickup Models This bulletin is to inform dealers of the release of rear wheel mud flaps. The above models that are exposed to extensive off-paved roads may benefit from the mud flaps. The mud flaps have been developed to minimize the amount of stones and/or mud that can impact and collect on the rear caliper and/or wheel rim. Please advise customers that the installation of these mud flaps and following the recommended off-road driving information provided in their Owner's Manual should greatly reduce the possibility of accelerated rear brake component wear and/or rim damage. Install the mud flap forward of each rear wheel using the following procedure. Important: Always work from outboard to inboard, drilling one hole at a time and securing with a fastener. Follow the sequence of the procedure. This will prevent distortion of the mud flap. 1. Raise the vehicle. Support the vehicle. 2. Locate the pickup box side panel rear brace. 3. Remove the existing outboard upper fastener on the brace. 4. Install the mud flap through the "V" of the brace. Install the previously removed fastener in the hole (2) of the mud flap to the brace. Do not tighten the fastener at this time. 5. Using the mud flap as a template, locate and mark the location of the hole (1) in the pickup box wheel house. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up > Page 8807 Important: After drilling the holes, apply the appropriate anti-corrosion primer. Refer to the GM Refinish Material Booklet # 4901 M-D (English) or # 4901-D-F (French) for additional information. 6. Center punch the marked location and drill a 6.35 mm (1/4 in) hole. Install the plastic retainer in the hole (1) of the mud flap. 7. Tighten fastener at the hole (2) location of the mud flap. Tighten Tighten the fastener to 25 N.m (18 lb ft). 8. For vehicles with short box, use the following procedure: 8.1. Push the mud flap to make contact with the rear side of the underbody cross sill and mark the location of the hole (3) of the mud flap. 8.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 8.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 8.4. Repeat the above steps for hole locations 4 and 6. 9. For vehicles with long box, use the following procedure: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up > Page 8808 9.1. Push the mud flap to make contact with the front side of the underbody cross sill and mark location of the hole (5) of the mud flap. 9.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 9.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 9.4. Repeat the above steps for hole location 6. 10. Repeat the above steps for the opposite side. Parts Information Parts are expected to be available from GMSPO on June 30, 2004. Warranty Information Please advise the customer that the mud flaps can be purchased as an accessory. Installation and/or cost of the mud flaps will not be covered under the vehicle's warranty. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 04-05-23-001 > Jan > 04 > Brakes - Low Pedal/Warning Message/Lamp ON Brake Caliper: Customer Interest Brakes - Low Pedal/Warning Message/Lamp ON Bulletin No.: 04-05-23-001 Date: January 21, 2004 TECHNICAL Subject: Low Brake Pedal, Red Brake Light On, Brake System Warning Message On (Tighten Rear Brake Caliper Banjo Bolts, Replace Gaskets and Install Shields) Models: 2000-2004 Chevrolet Silverado 2500 Series 2001-2003 Chevrolet Silverado HD 1500 Series 2001-2004 Chevrolet Suburban 2500 Series 2002-2004 Chevrolet Avalanche 2500 Series 2000-2004 GMC Sierra 2500 Series 2001-2003 GMC Sierra HD 1500 Series 2001-2004 GMC Yukon XL 2500 Series Condition Some customers may comment on a low brake pedal, red brake light on or the brake system warning message is on. Cause Under some extreme off-road conditions, debris may loosen the rear brake caliper banjo bolts causing a brake fluid leak. Correction Follow the service procedure below to inspect the rear brake caliper banjo bolts and gaskets and to install new slide bolts and rear caliper shield. 1. Verify the customer's concern. 2. Open the hood and install fender covers. 3. Clean off the brake master cylinder reservoir with brake clean, P/N 12378392, or equivalent. 4. Visually inspect the brake fluid level through the brake master cylinder reservoir. ^ If the brake warning light is on and the fluid level is low, continue with the next step. ^ If the brake warning light is on and the fluid level is NOT low, continue with Brake Warning Indicator Always On diagnostic. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 6. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheel. 7. Inspect the rear brake calipers for signs of fluid leaks around the banjo bolt area on both rear calipers. 8. Clean off the banjo bolt area with brake clean, P/N 12378392, or equivalent. Important: The banjo bolts copper gasket should not be reused. The banjo bolts may be reused if not damaged. 9. Remove the banjo bolt and discard the copper gaskets. 10. Assemble the two new copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. Important: Inspect both rear caliper banjo bolt torques even if only one side is leaking. Tighten Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 04-05-23-001 > Jan > 04 > Brakes - Low Pedal/Warning Message/Lamp ON > Page 8813 Tighten the bolt to 40 N.m (30 lb ft). Note: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II(R), P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 11. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes. 12. Remove the caliper bracket bolts. 13. Reposition the caliper and bracket on top of the rear leaf spring. 14. Remove the caliper guide pin bolts. 15. Install the two new brake caliper guide pin bolts from the Shield Kit, P/N 15188166. Tighten Tighten the caliper guide pin bolts to 108 N.m (80 lb ft). 16. Install one shield and two nuts from the shield kit. Tighten Tighten the shield retaining nuts to 45 N.m (33 lb ft). 17. Install the caliper and bracket onto the rotor. 18. Install the caliper bracket bolts. Tighten ^ For RPO JH5, tighten the caliper bracket bolts to 200 N.m (148 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 04-05-23-001 > Jan > 04 > Brakes - Low Pedal/Warning Message/Lamp ON > Page 8814 ^ For RPO JH6/JH7, tighten the caliper bracket bolts to 299 N.m (221 lb ft). 19. Repeat this procedure on the opposite side of the vehicle. 20. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 21. Lower the vehicle. 22. Top off the brake fluid reservoir. 23. Remove the fender covers and close the hood. 24. Road test the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 04-05-23-001 > Jan > 04 > Brakes - Low Pedal/Warning Message/Lamp ON > Page 8815 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up Brake Caliper: All Technical Service Bulletins Brakes/Wheels - Excessive Debris Build Up Bulletin No.: 04-05-23-005 Date: June 22, 2004 INFORMATION Subject: Availability of Rear Wheel Mud Flaps to Reduce Debris Build-up on Rear Brake Calipers and/or Rear Wheels Models: 1999-2004 Chevrolet Silverado Pickup Models 1999-2004 GMC Sierra Pickup Models This bulletin is to inform dealers of the release of rear wheel mud flaps. The above models that are exposed to extensive off-paved roads may benefit from the mud flaps. The mud flaps have been developed to minimize the amount of stones and/or mud that can impact and collect on the rear caliper and/or wheel rim. Please advise customers that the installation of these mud flaps and following the recommended off-road driving information provided in their Owner's Manual should greatly reduce the possibility of accelerated rear brake component wear and/or rim damage. Install the mud flap forward of each rear wheel using the following procedure. Important: Always work from outboard to inboard, drilling one hole at a time and securing with a fastener. Follow the sequence of the procedure. This will prevent distortion of the mud flap. 1. Raise the vehicle. Support the vehicle. 2. Locate the pickup box side panel rear brace. 3. Remove the existing outboard upper fastener on the brace. 4. Install the mud flap through the "V" of the brace. Install the previously removed fastener in the hole (2) of the mud flap to the brace. Do not tighten the fastener at this time. 5. Using the mud flap as a template, locate and mark the location of the hole (1) in the pickup box wheel house. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up > Page 8821 Important: After drilling the holes, apply the appropriate anti-corrosion primer. Refer to the GM Refinish Material Booklet # 4901 M-D (English) or # 4901-D-F (French) for additional information. 6. Center punch the marked location and drill a 6.35 mm (1/4 in) hole. Install the plastic retainer in the hole (1) of the mud flap. 7. Tighten fastener at the hole (2) location of the mud flap. Tighten Tighten the fastener to 25 N.m (18 lb ft). 8. For vehicles with short box, use the following procedure: 8.1. Push the mud flap to make contact with the rear side of the underbody cross sill and mark the location of the hole (3) of the mud flap. 8.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 8.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 8.4. Repeat the above steps for hole locations 4 and 6. 9. For vehicles with long box, use the following procedure: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up > Page 8822 9.1. Push the mud flap to make contact with the front side of the underbody cross sill and mark location of the hole (5) of the mud flap. 9.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 9.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 9.4. Repeat the above steps for hole location 6. 10. Repeat the above steps for the opposite side. Parts Information Parts are expected to be available from GMSPO on June 30, 2004. Warranty Information Please advise the customer that the mud flaps can be purchased as an accessory. Installation and/or cost of the mud flaps will not be covered under the vehicle's warranty. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 04-05-23-001 > Jan > 04 > Brakes - Low Pedal/Warning Message/Lamp ON Brake Caliper: All Technical Service Bulletins Brakes - Low Pedal/Warning Message/Lamp ON Bulletin No.: 04-05-23-001 Date: January 21, 2004 TECHNICAL Subject: Low Brake Pedal, Red Brake Light On, Brake System Warning Message On (Tighten Rear Brake Caliper Banjo Bolts, Replace Gaskets and Install Shields) Models: 2000-2004 Chevrolet Silverado 2500 Series 2001-2003 Chevrolet Silverado HD 1500 Series 2001-2004 Chevrolet Suburban 2500 Series 2002-2004 Chevrolet Avalanche 2500 Series 2000-2004 GMC Sierra 2500 Series 2001-2003 GMC Sierra HD 1500 Series 2001-2004 GMC Yukon XL 2500 Series Condition Some customers may comment on a low brake pedal, red brake light on or the brake system warning message is on. Cause Under some extreme off-road conditions, debris may loosen the rear brake caliper banjo bolts causing a brake fluid leak. Correction Follow the service procedure below to inspect the rear brake caliper banjo bolts and gaskets and to install new slide bolts and rear caliper shield. 1. Verify the customer's concern. 2. Open the hood and install fender covers. 3. Clean off the brake master cylinder reservoir with brake clean, P/N 12378392, or equivalent. 4. Visually inspect the brake fluid level through the brake master cylinder reservoir. ^ If the brake warning light is on and the fluid level is low, continue with the next step. ^ If the brake warning light is on and the fluid level is NOT low, continue with Brake Warning Indicator Always On diagnostic. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 6. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheel. 7. Inspect the rear brake calipers for signs of fluid leaks around the banjo bolt area on both rear calipers. 8. Clean off the banjo bolt area with brake clean, P/N 12378392, or equivalent. Important: The banjo bolts copper gasket should not be reused. The banjo bolts may be reused if not damaged. 9. Remove the banjo bolt and discard the copper gaskets. 10. Assemble the two new copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. Important: Inspect both rear caliper banjo bolt torques even if only one side is leaking. Tighten Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 04-05-23-001 > Jan > 04 > Brakes - Low Pedal/Warning Message/Lamp ON > Page 8827 Tighten the bolt to 40 N.m (30 lb ft). Note: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II(R), P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 11. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes. 12. Remove the caliper bracket bolts. 13. Reposition the caliper and bracket on top of the rear leaf spring. 14. Remove the caliper guide pin bolts. 15. Install the two new brake caliper guide pin bolts from the Shield Kit, P/N 15188166. Tighten Tighten the caliper guide pin bolts to 108 N.m (80 lb ft). 16. Install one shield and two nuts from the shield kit. Tighten Tighten the shield retaining nuts to 45 N.m (33 lb ft). 17. Install the caliper and bracket onto the rotor. 18. Install the caliper bracket bolts. Tighten ^ For RPO JH5, tighten the caliper bracket bolts to 200 N.m (148 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 04-05-23-001 > Jan > 04 > Brakes - Low Pedal/Warning Message/Lamp ON > Page 8828 ^ For RPO JH6/JH7, tighten the caliper bracket bolts to 299 N.m (221 lb ft). 19. Repeat this procedure on the opposite side of the vehicle. 20. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 21. Lower the vehicle. 22. Top off the brake fluid reservoir. 23. Remove the fender covers and close the hood. 24. Road test the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 04-05-23-001 > Jan > 04 > Brakes - Low Pedal/Warning Message/Lamp ON > Page 8829 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Page 8830 Brake Caliper: Specifications Brake Caliper Mounting Bolt Front ....................................................................................................................................................... 108 Nm (80 ft. lbs.) Brake Caliper Mounting Bolt Rear (15 series) ......................................................................................................................................... 42 Nm (31 ft. lbs.) Brake Caliper Mounting Bolt Rear (25/35 series) .................................................................................................................................. 108 Nm (80 ft. lbs.) Caliper Mounting Bracket Bolt Rear (JC5/JH5) ................................................................................................................................... 200 Nm (148 ft. lbs.) Caliper Mounting Bracket Bolt Rear (JH6) .......................................................................................................................................... 165 Nm (122 ft. lbs.) Caliper Mounting Bracket Bolt Rear (JH7) .......................................................................................................................................... 300 Nm (221 ft. lbs.) Caliper Mounting Bracket Bolt Rear (NYS) ........................................................................................................................................ 200 Nm (148 ft. lbs.) Caliper Mounting Bracket to Knuckle, Front (15 series) ...................................................................................................................... 175 Nm (129 ft. lbs.) Caliper Mounting Bracket to Knuckle, Front (25/35 series) ................................................................................................................. 300 Nm (221 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front Brake Caliper: Service and Repair Brake Caliper Replacement - Front Brake Caliper Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer Vehicle Lifting 5. Remove the tire and wheel assembly. 6. Compress the brake caliper pistons. ^ Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. ^ Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. ^ Remove the C-clamp from the caliper. 7. Clean all dirt and foreign material from the brake hose end. 8. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. Remove the brake hose to caliper bolt from the brake caliper. 9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. 10. Remove the brake hose from the caliper. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8833 11. Remove the 2 brake caliper mounting bolts. 12. Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result. Remove the brake caliper from the brake caliper mounting bracket. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper to the brake caliper mounting bracket. 2. Install the 2 brake caliper mounting bolts. ^ Tighten the 2 brake caliper mounting bolts to 108 Nm (80 ft. lbs.). 3. Remove the rubber cap or plug from the exposed brake hose fitting end. 4. Important: Install 2 New copper brake hose gaskets. Assemble the 2 New copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. 5. Install the brake hose to caliper bolt to the brake caliper. ^ Tighten the brake hose to caliper bolt to 40 Nm (30 ft. lbs.). 6. Bleed the hydraulic brake system. 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8834 Brake Caliper: Service and Repair Brake Caliper Overhaul - Front Brake Caliper Overhaul - Front ^ Tools Required J 45515 Brake Caliper Piston Boot Seal Installer Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Replace all the components included in the repair kits used to service this brake caliper. 2. Lubricate the rubber parts with new Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid to make assembly easier. 3. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. 4. The torque values specified are for dry, non-lubricated fasteners. 5. Perform the service operations on a clean bench, free from all mineral oil materials. 6. Remove the brake caliper from vehicle. Refer to Brake Caliper Replacement - Front. 7. Drain the brake fluid from the brake caliper. 8. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. Place a 25 mm (1 inch) block of wood between the caliper and the piston. 9. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the block of wood. 10. Carefully remove the brake caliper piston by directing low pressure compressed air into the brake caliper inlet hole. 11. Remove the C-clamp form the caliper. 12. Remove the block of wood from the caliper. 13. Install clean cloths to pad the interior of the caliper housing between the remaining caliper piston and the caliper body. 14. To cover the open caliper bore place a 25 mm (1 inch) block of wood between the caliper body and the brake caliper dust boot seal. 15. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the block of wood. 16. Carefully remove the brake caliper piston by directing low pressure compressed air into the brake caliper inlet hole. 17. Remove the C-clamp form the caliper. 18. Remove the block of wood from the caliper. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8835 19. Important: Care must be used when removing the piston boot and seal from the caliper. Use a small plastic or wood tool for removal. Do not use a metal tool because it may damage the caliper bore or seal groove. Remove the piston boots from the brake caliper. 20. Remove the piston seals from the brake caliper. 21. Remove the brake caliper bleeder valve and cap from the brake caliper. 22. Important: Do not use abrasives to clean the brake caliper piston. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent. 23. Dry the caliper piston bores and counterbores, and the piston with non-lubricated, filtered air. 24. Inspect all of the brake caliper parts as follows. ^ Piston - Inspect for scoring, nicks, cracks, wear, or corrosion. Replace the pistons if any damage is found. ^ Caliper Bore - Inspect for scoring, nicks, cracks, wear, or corrosion. Use crocus cloth to polish out light corrosion. Otherwise, replace the caliper. Do not hone the caliper bore. ^ Seal groove in the caliper bore for nicks or burrs. If found, replace the caliper. 25. Install the brake caliper bleeder valve and bleeder valve cap into the brake caliper. 26. Lubricate the new piston seal with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 10953488) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 27. Install the lubricated, new piston seals into the caliper bores. 28. Install the caliper piston into the caliper bore. 29. Install the new piston dust boot seal over the piston. 30. Using the J 45515 , fully seat the piston dust boot seal in the caliper. 31. Install the brake caliper to the vehicle. Refer to Brake Caliper Replacement - Front. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8836 Brake Caliper: Service and Repair Brake Caliper Replacement - Rear Brake Caliper Replacement - Rear (2500/3500 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer Vehicle Lifting 5. Remove the tire and wheel assembly. 6. Inspect the caliper operation. Refer to Brake Caliper Inspection. 7. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 8. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads. 9. Remove the C-clamp from the caliper. 10. Clean all dirt and foreign material from the brake hose end. 11. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. Remove the brake hose to caliper bolt from the brake caliper. 12. Remove the brake hose from the caliper. 13. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. 14. Loosen the brake caliper mounting bolts. Do not remove. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8837 15. Remove the brake caliper mounting bracket bolts. 16. Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result. Remove the brake caliper and the brake caliper mounting bracket as an assembly. 17. Remove the brake caliper mounting bolts. 18. Remove the brake caliper from the brake caliper mounting bracket. 19. Inspect the caliper assembly. Refer to Brake Caliper Inspection. 20. Remove the brake pads from the brake caliper mounting bracket. 21. Remove the anti-rattle clips from the brake caliper mounting bracket. 22. Inspect the brake caliper mounting bracket for cracks and/or damage. Replace if necessary. 23. Inspect the brake caliper mounting bracket bushings for damage and/or wear. Replace the bushings if necessary. 24. Perform the following procedure to replace the brake caliper mounting bracket bushings. ^ Insert a flat bladed tool between the bushing flange and the mounting bracket. ^ Work the tool around the bushing flange and remove the bushing from the mounting bracket. ^ Place a socket over the boot onto the bushing flange and install the bushing to the mounting bracket. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8838 1. Install the anti-rattle clips to the brake caliper mounting bracket. 2. Install the brake pads to the brake caliper mounting bracket. 3. Install the brake caliper to the brake caliper mounting bracket. 4. Perform the following procedure before installing the brake caliper mounting bracket bolts and the brake caliper mounting bolts: 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 5. Install the brake caliper mounting bolts. Do not tighten. 6. Install the brake caliper mounting bracket and brake caliper as an assembly. 7. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper mounting bracket bolts. ^ Tighten the brake caliper mounting bracket bolts to 300 Nm (221 ft. lbs.). 8. Tighten the brake caliper mounting bolts. ^ Tighten the brake caliper mounting bolts to 108 Nm (80 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8839 9. Remove the rubber cap or plug from the exposed brake hose fitting end. 10. Important: Install 2 new copper brake hose gaskets. Assemble the 2 new copper brake hose gaskets and the brake hose inlet fitting bolt to the brake hose. 11. Connect the brake hose at the caliper by installing the brake hose to caliper bolt. ^ Tighten the bolt to 40 Nm (30 ft. lbs.). 12. Bleed the hydraulic brake system. 13. Install the tire and wheel assembly. 14. Lower the vehicle. 15. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8840 Brake Caliper: Service and Repair Brake Caliper Overhaul - Rear Brake Caliper Overhaul - Rear (25/35 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Disassembly Procedure Important: ^ Replace all the components included in the repair kits used to service this brake caliper. ^ Lubricate the rubber parts with clean brake fluid to make assembly easier. ^ The torque values specified are for dry, non lubricated fasteners. ^ Perform the service operations on a clean bench, free from all mineral oil materials. 1. Remove the brake caliper from the vehicle. 2. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Place a thin piece wood in front of the pistons in order to prevent damage. Remove the pistons by directing compressed air into the brake hose inlet fitting port of the brake caliper housing. 3. Remove the 2 pistons. 4. Remove the 2 piston boots. 5. Remove the 2 piston seals. 6. Remove the brake caliper bleed screw cap. 7. Remove the brake caliper bleed screw. 8. Inspect the brake caliper bores and the piston seal grooves for scoring and corrosion. If you find excessive scoring or corrosion around the 2 piston seal areas replace the brake caliper housing. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8841 9. Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and replace the brake caliper mounting bracket if needed. 10. Clean all the residue from the brake pad guiding surfaces on the brake caliper housing and the brake caliper mounting bracket. 11. Clean all the parts not included in the repair kit with denatured alcohol. 12. Dry all the parts with non lubricated filtered compressed air. 13. Blow out all passages in the brake caliper housing and the brake caliper bleeder valve. Assembly Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper bleed screw. ^ Tighten the brake caliper bleed screw to 12 Nm (106 inch lbs.). 2. Install the brake caliper bleed screw cap. 3. Lubricate the new piston seal and the brake caliper bore seal groove with brake fluid. 4. Install new the seal into the brake caliper bore seal groove. 5. Ensure that the seal is not twisted. 6. Lubricate the brake caliper bore and the piston with brake fluid. 7. Install the boot and the piston. 1. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. 2. Seat the boot into the brake caliper bore groove. Slide the piston into the brake caliper bore. 3. Push down the piston to the bottom of the brake caliper bore. 4. Ensure that the boot properly seats into the piston groove and into the groove in the brake caliper bore. 5. Repeat steps 5 and 6 for the remaining piston. 8. Install the brake caliper to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8842 Brake Caliper: Service and Repair Brake Caliper Replacement - Front Brake Caliper Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer Vehicle Lifting 5. Remove the tire and wheel assembly. 6. Compress the brake caliper pistons. ^ Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. ^ Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. ^ Remove the C-clamp from the caliper. 7. Clean all dirt and foreign material from the brake hose end. 8. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. Remove the brake hose to caliper bolt from the brake caliper. 9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. 10. Remove the brake hose from the caliper. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8843 11. Remove the 2 brake caliper mounting bolts. 12. Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result. Remove the brake caliper from the brake caliper mounting bracket. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper to the brake caliper mounting bracket. 2. Install the 2 brake caliper mounting bolts. ^ Tighten the 2 brake caliper mounting bolts to 108 Nm (80 ft. lbs.). 3. Remove the rubber cap or plug from the exposed brake hose fitting end. 4. Important: Install 2 New copper brake hose gaskets. Assemble the 2 New copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. 5. Install the brake hose to caliper bolt to the brake caliper. ^ Tighten the brake hose to caliper bolt to 40 Nm (30 ft. lbs.). 6. Bleed the hydraulic brake system. 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8844 Brake Caliper Overhaul - Front Brake Caliper Overhaul - Front ^ Tools Required J 45515 Brake Caliper Piston Boot Seal Installer Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Replace all the components included in the repair kits used to service this brake caliper. 2. Lubricate the rubber parts with new Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid to make assembly easier. 3. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. 4. The torque values specified are for dry, non-lubricated fasteners. 5. Perform the service operations on a clean bench, free from all mineral oil materials. 6. Remove the brake caliper from vehicle. Refer to Brake Caliper Replacement - Front. 7. Drain the brake fluid from the brake caliper. 8. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. Place a 25 mm (1 inch) block of wood between the caliper and the piston. 9. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the block of wood. 10. Carefully remove the brake caliper piston by directing low pressure compressed air into the brake caliper inlet hole. 11. Remove the C-clamp form the caliper. 12. Remove the block of wood from the caliper. 13. Install clean cloths to pad the interior of the caliper housing between the remaining caliper piston and the caliper body. 14. To cover the open caliper bore place a 25 mm (1 inch) block of wood between the caliper body and the brake caliper dust boot seal. 15. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the block of wood. 16. Carefully remove the brake caliper piston by directing low pressure compressed air into the brake caliper inlet hole. 17. Remove the C-clamp form the caliper. 18. Remove the block of wood from the caliper. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8845 19. Important: Care must be used when removing the piston boot and seal from the caliper. Use a small plastic or wood tool for removal. Do not use a metal tool because it may damage the caliper bore or seal groove. Remove the piston boots from the brake caliper. 20. Remove the piston seals from the brake caliper. 21. Remove the brake caliper bleeder valve and cap from the brake caliper. 22. Important: Do not use abrasives to clean the brake caliper piston. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent. 23. Dry the caliper piston bores and counterbores, and the piston with non-lubricated, filtered air. 24. Inspect all of the brake caliper parts as follows. ^ Piston - Inspect for scoring, nicks, cracks, wear, or corrosion. Replace the pistons if any damage is found. ^ Caliper Bore - Inspect for scoring, nicks, cracks, wear, or corrosion. Use crocus cloth to polish out light corrosion. Otherwise, replace the caliper. Do not hone the caliper bore. ^ Seal groove in the caliper bore for nicks or burrs. If found, replace the caliper. 25. Install the brake caliper bleeder valve and bleeder valve cap into the brake caliper. 26. Lubricate the new piston seal with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 10953488) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 27. Install the lubricated, new piston seals into the caliper bores. 28. Install the caliper piston into the caliper bore. 29. Install the new piston dust boot seal over the piston. 30. Using the J 45515 , fully seat the piston dust boot seal in the caliper. 31. Install the brake caliper to the vehicle. Refer to Brake Caliper Replacement - Front. Brake Caliper Replacement - Rear Brake Caliper Replacement - Rear (2500/3500 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8846 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer Vehicle Lifting 5. Remove the tire and wheel assembly. 6. Inspect the caliper operation. Refer to Brake Caliper Inspection. 7. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 8. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads. 9. Remove the C-clamp from the caliper. 10. Clean all dirt and foreign material from the brake hose end. 11. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. Remove the brake hose to caliper bolt from the brake caliper. 12. Remove the brake hose from the caliper. 13. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. 14. Loosen the brake caliper mounting bolts. Do not remove. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8847 15. Remove the brake caliper mounting bracket bolts. 16. Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result. Remove the brake caliper and the brake caliper mounting bracket as an assembly. 17. Remove the brake caliper mounting bolts. 18. Remove the brake caliper from the brake caliper mounting bracket. 19. Inspect the caliper assembly. Refer to Brake Caliper Inspection. 20. Remove the brake pads from the brake caliper mounting bracket. 21. Remove the anti-rattle clips from the brake caliper mounting bracket. 22. Inspect the brake caliper mounting bracket for cracks and/or damage. Replace if necessary. 23. Inspect the brake caliper mounting bracket bushings for damage and/or wear. Replace the bushings if necessary. 24. Perform the following procedure to replace the brake caliper mounting bracket bushings. ^ Insert a flat bladed tool between the bushing flange and the mounting bracket. ^ Work the tool around the bushing flange and remove the bushing from the mounting bracket. ^ Place a socket over the boot onto the bushing flange and install the bushing to the mounting bracket. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8848 1. Install the anti-rattle clips to the brake caliper mounting bracket. 2. Install the brake pads to the brake caliper mounting bracket. 3. Install the brake caliper to the brake caliper mounting bracket. 4. Perform the following procedure before installing the brake caliper mounting bracket bolts and the brake caliper mounting bolts: 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 5. Install the brake caliper mounting bolts. Do not tighten. 6. Install the brake caliper mounting bracket and brake caliper as an assembly. 7. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper mounting bracket bolts. ^ Tighten the brake caliper mounting bracket bolts to 300 Nm (221 ft. lbs.). 8. Tighten the brake caliper mounting bolts. ^ Tighten the brake caliper mounting bolts to 108 Nm (80 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8849 9. Remove the rubber cap or plug from the exposed brake hose fitting end. 10. Important: Install 2 new copper brake hose gaskets. Assemble the 2 new copper brake hose gaskets and the brake hose inlet fitting bolt to the brake hose. 11. Connect the brake hose at the caliper by installing the brake hose to caliper bolt. ^ Tighten the bolt to 40 Nm (30 ft. lbs.). 12. Bleed the hydraulic brake system. 13. Install the tire and wheel assembly. 14. Lower the vehicle. 15. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. Brake Caliper Overhaul - Rear Brake Caliper Overhaul - Rear (25/35 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Disassembly Procedure Important: ^ Replace all the components included in the repair kits used to service this brake caliper. ^ Lubricate the rubber parts with clean brake fluid to make assembly easier. ^ The torque values specified are for dry, non lubricated fasteners. ^ Perform the service operations on a clean bench, free from all mineral oil materials. 1. Remove the brake caliper from the vehicle. 2. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Place a thin piece wood in front of the pistons in order to prevent damage. Remove the pistons by directing compressed air into the brake hose inlet fitting port of the brake caliper housing. 3. Remove the 2 pistons. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8850 4. Remove the 2 piston boots. 5. Remove the 2 piston seals. 6. Remove the brake caliper bleed screw cap. 7. Remove the brake caliper bleed screw. 8. Inspect the brake caliper bores and the piston seal grooves for scoring and corrosion. If you find excessive scoring or corrosion around the 2 piston seal areas replace the brake caliper housing. 9. Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and replace the brake caliper mounting bracket if needed. 10. Clean all the residue from the brake pad guiding surfaces on the brake caliper housing and the brake caliper mounting bracket. 11. Clean all the parts not included in the repair kit with denatured alcohol. 12. Dry all the parts with non lubricated filtered compressed air. 13. Blow out all passages in the brake caliper housing and the brake caliper bleeder valve. Assembly Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper bleed screw. ^ Tighten the brake caliper bleed screw to 12 Nm (106 inch lbs.). 2. Install the brake caliper bleed screw cap. 3. Lubricate the new piston seal and the brake caliper bore seal groove with brake fluid. 4. Install new the seal into the brake caliper bore seal groove. 5. Ensure that the seal is not twisted. 6. Lubricate the brake caliper bore and the piston with brake fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8851 7. Install the boot and the piston. 1. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. 2. Seat the boot into the brake caliper bore groove. Slide the piston into the brake caliper bore. 3. Push down the piston to the bottom of the brake caliper bore. 4. Ensure that the boot properly seats into the piston groove and into the groove in the brake caliper bore. 5. Repeat steps 5 and 6 for the remaining piston. 8. Install the brake caliper to the vehicle. Brake Caliper Bracket Replacement - Front Brake Caliper Bracket Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. Refer to Brake Caliper Replacement Front. 2. Remove the brake pads. 3. Remove the anti-rattle clips from the brake caliper bracket. 4. Remove the brake caliper bracket mounting bolts (2). 5. Remove the brake caliper bracket (1). 6. Remove any contaminants or foreign material from the inside ends of the brake caliper bracket. 7. Clean the mounting surface and threads of the brake caliper bracket. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8852 1. Install the brake caliper bracket (1). 2. Perform the following procedure before installing the brake caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the caliper bracket mounting bolts (2). ^ Tighten the brake caliper bracket mounting bolts to 175 Nm (121 ft. lbs.) (15 Series). ^ Tighten the brake caliper bracket mounting bolts to 300 Nm (221 ft. lbs.) (25 and 35 Series). 4. Install the anti-rattle clips to the brake caliper bracket. 5. Install the brake pads to the brake caliper bracket. 6. Slide the brake pads in until they contact the rotor. 7. Install the brake caliper. Refer to Brake Caliper Replacement - Front. 8. Install the tire and wheel assembly. 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of it's travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 10-11 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Brake Caliper Bracket Replacement - Rear Brake Caliper Bracket Replacement - Rear (15/25 Series w/o NYS) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper from the brake caliper mounting bracket and support the brake caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake hose from the brake caliper. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8853 4. Remove the brake pads from the brake caliper mounting bracket. 5. Remove the anti-rattle clips from the brake caliper bracket. 6. Remove the brake caliper bracket mounting bolts (2). 7. Remove the brake caliper bracket (1). 8. Remove any contaminants or foreign material from the inside ends of the brake caliper bracket. 9. Clean the mounting surface and threads of the brake caliper bracket. Installation Procedure 1. Install the brake caliper bracket (1). 2. Perform the following procedure before installing the brake caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the caliper bracket mounting bolts (2). For vehicles equipped with JH5 brake systems, tighten the caliper bracket mounting bolts to 200 Nm (148 ft. lbs.). For vehicles equipped with JH6/JH7 brake systems, tighten the caliper bracket mounting bolts to 300 Nm (221 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8854 4. Install the anti-rattle clips to the brake caliper mounting bracket. 5. Install the brake pads to the brake caliper mounting bracket. 6. Slide the brake pads in until they contact the rotor. 7. Install the brake caliper. 8. Install the tire and wheel assembly. 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of it's travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 10-11 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Disc Brake Hardware Replacement - Front Disc Brake Hardware Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. Refer to Brake Caliper Replacement Front. 4. Remove the disc brake pads from the disc brake caliper mounting bracket. 5. Remove the disc brake pad retainers from the disc brake caliper mounting bracket. 6. Inspect the disc brake hardware. Refer to Disc Brake Mounting and Hardware Inspection - Front. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8855 7. Remove the caliper pin boots (4) from the disc brake caliper mounting bracket (3). Installation Procedure 1. Lubricate the front brake caliper bushings, bolts and seals with high temperature silicone brake lubricant. 2. Install the caliper pin boots (4) to the disc brake caliper mounting bracket (3). 3. Install the disc brake pad retainers to the disc brake caliper mounting bracket. 4. Install the disc brake pads to the disc brake caliper mounting bracket. 5. Install the disc brake caliper to the caliper mounting bracket. Refer to Brake Caliper Replacement - Front. 6. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance. 7. Slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 6-7 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Disc Brake Hardware Replacement - Rear Disc Brake Hardware Replacement - Rear Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer Vehicle Lifting 2. Remove the tire and wheel assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8856 3. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper from the brake caliper mounting bracket and support the brake caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake hose from the caliper. 4. Remove the disc brake pads from the brake caliper mounting bracket. 5. Remove the disc brake pad retainers from the brake caliper mounting bracket. 6. Remove the caliper slide pins (5) from the brake caliper mounting bracket (3). 7. Remove the caliper slide pin boots (4) from the brake caliper mounting bracket. 8. Inspect the disc brake hardware. Installation Procedure 1. Lubricate the brake caliper mounting bracket bushings and the caliper slide pins with high temperature silicone brake lubricant. 2. Install the caliper slide pin boots (4) to the disc brake caliper mounting bracket. 3. Install the caliper slide pins (5) to the brake caliper mounting bracket (3). 4. Install the disc brake pad retainers to the brake caliper mounting bracket. 5. Install the disc brake pads to the brake caliper mounting bracket. 6. Install the disc brake caliper to the brake caliper mounting bracket. 7. With the engine OFF, gradually apply the brake pedal approximately 2/3 of it's travel distance. 8. Slowly release the brake pedal. 9. Wait 15 seconds, then repeat steps 7-8 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 10. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Replace the disc brake pads when the friction surface is worn to within 0.76 mm (0.030 inch) of the mounting plates. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement - Front Brake Pad: Service and Repair Brake Pads Replacement - Front Brake Pads Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer Vehicle Lifting 5. Remove the tire and wheel assembly. 6. Inspect the brake caliper operation. Refer to Brake Caliper Inspection. 7. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper from the brake caliper mounting bracket and support the brake caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake hose from the brake caliper. Refer to Brake Caliper Replacement - Front. 8. Remove the disc brake pads from the brake caliper mounting bracket. 9. Remove and discard the anti-rattle clips from the brake caliper mounting bracket. 10. Inspect the brake caliper and brake caliper mounting bracket. Refer to Brake Caliper Inspection. Installation Procedure 1. Install new anti-rattle clips to the brake caliper mounting bracket. 2. Install the disc brake pads to the brake caliper mounting bracket. ^ Install the inner pad, 1 wear indicator. ^ Install the outer pad, 2 wear indicators. 3. Install the brake caliper. Refer to Brake Caliper Replacement - Front. 4. Install the tire and wheel assembly. 5. Remove the safety stands. 6. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement - Front > Page 8862 7. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of it's travel distance. 8. Slowly release the brake pedal. 9. Wait 15 seconds, then repeat steps 7-8 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 10. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. 11. Burnish the disc brake pads and rotors. Refer to Burnishing Pads and Rotors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement - Front > Page 8863 Brake Pad: Service and Repair Brake Pads Replacement - Rear Brake Pads Replacement - Rear (All except 1500 Series W/O NYS) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer Vehicle Lifting 5. Remove the tire and wheel assembly. 6. Inspect the brake caliper operation. Refer to Brake Caliper Inspection. 7. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper from the brake caliper mounting bracket and support the brake caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake hose from the brake caliper. 8. Inspect the brake caliper assembly. Refer to Brake Caliper Inspection. 9. Remove the disc brake pads from the brake caliper mounting bracket. 10. Remove and discard the anti-rattle clips from the brake caliper mounting bracket. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement - Front > Page 8864 1. Install the anti-rattle clips to the brake caliper mounting bracket. 2. Install the disc brake pads to the brake caliper mounting bracket. 3. Install the brake caliper to the brake caliper mounting bracket. 4. Install the tire and wheel assembly. 5. Remove the safety stands. 6. Lower the vehicle. 7. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of it's travel distance. 8. Slowly release the brake pedal. 9. Wait 15 seconds, then repeat steps 7-8 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 10. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. 11. Burnish the brakes pads and rotors as necessary. Refer to Burnishing Pads and Rotors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement - Front > Page 8865 Brake Pad: Service and Repair Burnishing Pads and Rotors Burnishing Pads and Rotors Caution: Refer to Road Test Caution in Service Precautions. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures Technical Service Bulletin # 00-05-22-002L Date: 090326 Brakes- Disc Brake Warranty Service And Procedures INFORMATION Bulletin No.: 00-05-22-002L Date: March 26, 2009 Subject: Disc Brake Warranty Service and Procedures Models: 1999-2010 GM Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 1999-2004 Isuzu Light Duty Trucks (Canada Only) 2005-2009 Saab 9-7X (Canada Only) 1999-2010 Saturn Vehicles (Canada Only) EXCLUDING 2009-2010 Chevrolet Corvette ZR1 Supercede: This bulletin is being revised to inform you that due to improvements in vehicle brake corner and wheel design, assembly plant build processes and dealership required tools like the On-Car Lathe, measuring for Lateral Run Out (LRO) is no longer a required step when performing base brake service. Due to this change, you are no longer required to enter the LRO measurement on the repair order or in the warranty system failure code section. The bulletin information below and the base brake labor operations have been updated accordingly. Due to this change it is more important than ever to properly maintain your brake lathe (per the Brake Lathe Calibration Procedure in this bulletin). Please discard Corporate Bulletin Number 00-05-22-002K (Section 05 Brakes). For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional information, the Service Technical College lists a complete index of available Brake courses. This information can be accessed at www.gmtraining.com > resources > training materials > brakes courseware index. In Canada, refer to Service Know How course 55040.00V and Hydraulic Brake Certification program 15003.16H. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM BRAKE SERVICE. The following four (4) key steps are a summary of this bulletin and are REQUIRED in completing a successful brake service. 1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) determine rotor clean-up/refinish/replace 2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel 3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness (REQUIRED on Repair Order) Important If it is determined the rotor needs to be refinished, verify lathe equipment is properly calibrated. 4. Properly reassemble the brake corner using proper torque tools, torque specification and torque sequence - wheel lug nuts. * The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec after refinish and not the discard spec. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8870 Bulletin Format ***REPAIR ORDER REQUIRED DOCUMENTATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8871 Important When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake Burnish), the following two rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor Thickness are required and MUST be written/documented on the repair order, or for your convenience, complete the form (GM Brake Service Repair Order Documentation for Required Measurements) shown above and attach it to the repair order. If the Warranty Parts Center generates a request, this Documentation/Form must be attached to the repair order that is sent back. Important Documentation of brake lathe maintenance and calibration as recommended by the lathe manufacturer must be available for review upon request. Repair Order Documentation - Rotor Original And Refinished Thickness - REQUIRED When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before refinish) and REFINISHED thickness (measured thickness after refinish) MUST be written/documented on the repair order hard copy for each rotor serviced. If a rotor replacement is necessary, only the original thickness measurement needs to be recorded. Repair Order Documentation - Explanation of Part Replacement - REQUIRED If replacement of a brake component is necessary, proper documentation on the repair order is required. See the following examples: ^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a prior brake service. After rotor measurement, it was determined that refinishing the rotor again would take it under the Minimum Thickness specification. ^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads contaminated by fluid leak at caliper. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8872 TOOL INFORMATION CORRECTION PLATE PART INFORMATION Refer to TSB 01-05-23-001 for the Brake Align(R) application chart. For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be submitted in the Net Amount at cost plus 40%. Brake Align(R) Run-Out Correction Plates are available through the following suppliers: - Dealer Equipment and Services - Brake Align(R) LLC (U.S. Dealers Only) * We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items, which may be available from other sources. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8873 WARRANTY INFORMATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8874 WORKSHEET - BRAKE LATHE CALIBRATION Important Brake lathe calibration should be performed and recorded monthly or if you are consistently measuring high LRO after rotor refinishing. Disclaimer GM Brake Service Procedure GM BRAKE SERVICE PROCEDURE 1. Remove the wheel and caliper. 2. Measure rotor thickness. In order to determine if the rotor can be refinished, do the following steps: Important Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8875 If performing routine Brake Service for worn pads only, and the rotors are not damaged and measure within specification - DO NOT REFINISH ROTORS. 1. Remove the rotor(s). 2. Measure the rotor for original thickness using a brake micrometer. Multiple measure points should be taken and the lowest measurement should be recorded. 3. Reference the Minimum Thickness specification stamped on the backside of the rotor or SI for Minimum Thickness specification/other. In most cases, the rotor should be refinished unless the measurement taken makes it obvious that refinishing the rotor would take the measurement under the Minimum Thickness specification (then replacement is necessary). DO NOT use any other manufacturers rotor specifications. 3. ***Record the lowest ORIGINAL rotor thickness measurement on the repair order hard copy as noted in the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 4. Clean all of the mating surfaces between the hub, the rotor and the wheel using the J 42450A Wheel Hub Cleaning Kit and J 41013 - Whiz Wheel(R). If rotors are not to be refinished - Go To Step 8. Important Cleaning all mating surfaces and making them free of corrosion, burrs and other debris (which includes removal of Hubless rotors) is critical and MUST be performed whether using an On-Car or Bench Lathe Refinish Procedure. 5. Be sure to follow the appropriate refinishing procedure listed below for the type of lathe you are using. Important Only replace the rotors if they do not meet the Minimum Thickness specification. Important DO NOT REFINISH NEW ROTORS. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important Prior to making the cut, install the recommended clip-on style disc silencer supplied with the lathe. Use of this silencer is critical to prevent chatter from occurring during the cut. Bench Type Lathe 1. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. 2. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information, see the "Brake Lathe Calibration Procedure (Bench-Type)" section in this bulletin. 3. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn 4. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 5. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 6. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 7. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. On-Car Type Lathe 1. Reinstall the rotor(s). Important Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8876 When using the On-Car lathe on vehicles equipped with limited slip (or posi-trac) rear system, it is critical that the rear drive shaft is disconnected/disengaged prior to operation of the On-Car lathe. Remember to mark and re-index the drive shaft correctly on re-assembly to prevent creating driveline vibration. Whenever the lathe drive motor is being switched on, the operator MUST keep their body out of the wheel well area until the machine has reached its normal operating RPM. 2. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. Important When raising the vehicle on the lift, be sure to have it at a good working height (waist high is average) to accommodate mounting the On-Car lathe. Optimally, the center piston on the lathe trolley will be mid-travel. If the lathe trolley center piston is completely compressed (bottoming out) or inversely fully extended and hanging off the vehicle hub, this could affect the calibration time of the lathe. 3. Select the correct adapter for the vehicle you're working on and mount it to the hub with the vehicle lug nuts. Hand tighten 34-41 Nm (25-30 lb ft) the nuts using equal torque. DO NOT use impact wrenches, excessive torque will damage the adapter. Important Ensure the adapter sits flush on the rotor hat surface. Be sure to remove any rust, rotor retaining clips, etc. that may preclude the adapter from sitting flat on the mounting surface. 4. Connect the lathe to the adapter, turn on the lathe and activate the computer to compensate for run-out in the hub. 5. Once the computer indicates the compensation process was successful, on the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 6. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 7. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 8. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 9. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. 10. Dismount the lathe, but leave the lathe adapter attached to the vehicle. 6. Once the rotor has been properly machined, wash the rotor with soap and water (use a mild dish washing soap) or wipe it clean with GM approved brake cleaner, P/N 88862650 (Canadian P/N 88901247). Important Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as a by-product of machining to the pad material during the seating process, thus reducing the opportunity for squeaks or other noises to occur. 7. ***Record the REFINISHED rotor thickness measurement on the repair order hard copy. Refer to the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 8. Setting up to measure for Lateral Run Out (LRO): Important Measuring for Lateral Run Out (LRO) (steps 8 - 15) is no longer required however, these steps are being left in the overall procedure as a good check to be performed in the case of a repeat pulsation complaint. If you are not checking for LRO, go to step 16. Bench-Type Lathe 1. Ensure that the mating surfaces of the rotor hat section and the hub mating surface are clean and free of debris. 2. Mount the new, original or refinished rotor onto the vehicle hub. Important Always hold the rotor on the bottom half so any debris that may be dislodged from the vents will fall out instead of falling into the mounting area. Any movement or jarring from the rotor falling over on the studs can release rust from the vents on the rotor. 3. Tilt the top of the rotor in towards the vehicle so you can see the studs and ease the rotor onto the studs. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8877 4. Slide the rotor all the way to the hub and hold it in place until you have placed one of the conical washers (with the tapered hole side facing out) and run the first lug nut up tight by hand so the rotor doesn't move when you release it. 5. Place the conical washers on the rest of the studs (with the tapered hole side facing out), start and snug the lug nuts by hand. 6. Using the one half inch drive impact wrench and a torque stick (J 39544) or equivalent, start with the lug nut opposite of the one you first tightened by hand and tighten the lug nuts using a star pattern until they touch the hub but do not completely torque. Then again, starting with the first lug nut you tightened by hand, tighten all the lug nuts in a star pattern to the specific vehicle torque specification. 7. DO NOT reinstall the caliper or the wheel at this time. On-Car Type Lathe 1. Leave the On-Car adapter on the wheel. 2. Proceed to Step 9. 9. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor outboard friction surface approximately 6.35 mm (0.25 in) from the rotor's outer edge. The stylus should be perpendicular to the friction surface of the rotor. Important Make sure the dial indicator needle tip is screwed tight, a loose tip could cause false readings. 10. Measure for LRO. Follow the procedure below to determine if the LRO is within specification (0.050 mm (0.002 in) or LESS). 1. Rotate the rotor and locate the point on the rotor where the lowest dial indicator reading is indicated and set the dial indicator to zero. 2. Rotate the rotor from the low point and locate the point with the highest dial indicator reading (rotor "high spot"). Note the amount and mark the location of the "high spot" on the rotor and mark the closest wheel stud relative to this location. If the high point falls between two studs, mark both studs. In instances where the vehicle has "capped lug nuts" you should mark the hub. 11. If the Lateral Run Out (LRO) measurement is 0.050 mm (0.002 in) or LESS, no correction is necessary. Go to Step 15 if this is the first rotor completed. Go to Step 16 if this is the second rotor completed. If the LRO is GREATER than 0.050 mm (0.002 in), go to Step 12. 12. If the LRO measurement is greater than 0.050 mm (0.002 in), use the following procedure to correct for LRO: Important If the LRO measurement is over 0.279 mm (0.011 in), determine the source or cause of the LRO and correct it (i.e. verify drive axle nut torque specification, refinished rotor is source of LRO due to a lathe qualification issue - see "Brake Lathe Calibration Procedure"). Hubless Rotor 1. Remove the rotor and using the Brake Align(R) application chart (found in TSB 01-05-23-001B), choose the correct plate to bring the rotor LRO to 0.050 mm (0.002 in) or less. The plates come in 0.0762 mm (0.003 in), 0.1524 mm (0.006 in) and 0.2286 (0.009 in) compensation. For more information on proper plate selection, see the instruction video/DVD included in the "Brake Align(R)" kit or TSB 01-05-23-001B. 2. Align the V-notch of the selected Brake Align(R) correction plate to the marked wheel stud ("high spot") or between the two points marked (if the "high spot" is between two wheel studs). Important IF Brake Align(R) Correction Plates are not available for the vehicle being serviced, refer to SI Document - Brake Rotor Assembled Lateral Runout Correction for correcting LRO. Important Per Brake Align(R) manufacturer, NEVER attempt to stack two or more Correction Plates together on one hub. NEVER attempt to reuse a previously installed Correction Plate. 3. Reinstall the rotor using the same method and precautions as the first time - found in Step 8. Make sure to index the rotor correctly to the marks made in step 10, otherwise LRO will be comprised. Hubbed / Captured / Trapped Rotor 1. Measure the rotor thickness. 2. Refinish or replace the rotor (see Service Information for further details). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8878 13. Use a Dial Indicator to measure the rotor to verify the LRO is within specification. 14. If using, BENCH LATHE - DO NOT remove conical washers and lug nuts at this time. ON-CAR LATHE - You must remove adapter and install conical washers and lug nuts to retain rotor position. Important For Hubless rotor design, while removing the adapter, you must hold the rotor tight to the hub and install the top conical washer and lug nut first to ensure no debris falls between the surface while removing the adapter. Then, install the remaining conical washers and lug nuts. Otherwise, LRO will be comprised. 15. Perform Steps 1 through 7 on the opposite side of the vehicle (steps 1-12, if performing LRO). 16. Reinstall the rotors on both sides of the vehicle and perform the following steps: 1. Reinstall the calipers and pads. 2. Pump the brakes to pressurize the calipers. 3. Remove the lug nuts/conical washers. 4. Install and properly torque the wheels. Important It is critical to follow the star pattern wheel torque procedure and use the proper tools (torque stick or torque wrench) as referenced in SI. 17. Road test the vehicle to verify the repairs. Brake Lathe Calibration Procedure BRAKE LATHE CALIBRATION PROCEDURE Calibration of the brake lathe should be performed and recorded monthly or whenever post-service brake rotor LRO measurements are consistently reading above specification. BENCH-TYPE LATHE Use the following procedure to calibrate a Bench-type brake lathe: 1. After refinishing a rotor, loosen the arbor nut and while holding the inside bell clamp to keep it from rotating, rotate the rotor 180 degrees. 2. Retighten the arbor nut and set the dial indicator on the rotor using the same instructions as checking the run out on the vehicle. 3. Rotate the arbor and read the runout. 4. Divide the reading by two and this will give you the amount of runout the lathe is cutting into the rotor. Important If there is any runout, you will need to machine the inside bell clamp in place on the lathe (this procedure is for a Bench type lathe ONLY, DO NOT machine inside the bell clamp on an On-Car type lathe). Machining the Inside Bell Clamp (Bench Type Lathe Only) Any nicks or burrs on the shoulder of the arbor must be removed. An 80-grit stone can be used to accomplish this. Spray WD-40(R) on the shoulder and with the lathe running, hold the stone flat against the shoulder surface using slight pressure. When the burrs are gone, clean the surface. Burrs must also be removed from the hub of the inside bell clamp. This can be accomplished with the stone and WD-40(R). Keep the stone flat on the hub while removing the burrs. After removing the burrs, clean the hub. Place the bell clamp on the arbor of the lathe and use the small radius adapters first and then spacers to allow you to tighten the arbor nut to secure the bell clamp to the lathe. Position the tool bit in the left hand of the rotor truer so you can machine the face of the bell clamp. Machine the face of the bell clamp taking just enough off of it to cut the full face of the clamp the full 360 degrees. Before you loosen the arbor nut, match mark the hub of the bell clamp to the arbor and line up these marks before machining a rotor. A magic marker can be used to make the match marks. Machine a rotor and recheck the calibration. Repeat this procedure on all Inside Bell Clamps used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8879 Important If runout is still present, contact the brake lathe supplier. ON-CAR TYPE LATHE Use the following procedure to calibrate an On-Car brake lathe: 1. Connect the lathe to a vehicle using the appropriate adapter. 2. Attach a vise-grip dial indicator to a fixed point in the wheel well and bring the dial indicator to a flat surface on the cutting head. 3. Turn on the lathe and press the "start" button so the lathe begins to compensate. 4. Once compensation is complete, note the runout as measured by the dial indicator. Measured runout at this point is overstated given that it is outside the rotor diameter. 5. If runout is in excess of 0.1016 mm (0.004 in) (0.050 mm (0.002 in) as measured within the rotor diameter), calibration must be tightened. Follow manufacturer's instructions for tightening the calibration of the lathe. This information is found in the manual supplied with the lathe. Important If the machine is taking a long time to compensate during normal use, prior to checking the lathe calibration, it is recommended that the machine be disconnected from the adapter and the adapter (still connected to the vehicle) is rotated 180 degrees and the machine reattached. This will accomplish two things: - It will re-verify the machine is properly attached to the adapter. - It will change the location of the runout (phase) relative to the machine and thus possibly allow for quick compensation as a result of the position change. The following information has been added as a reference to ensure your Pro-Cut PFM lathe provides a consistent smooth surface finish over long term usage. Cutting Tips / Depth of Cut / Tip Life The cutting tips must be right side up. Reference marks always face up. The cutting tips may not have chips or dings in the surface of the points. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. When cleaning or rotating the cutting bits, make sure that the seat area for the tip on the tool is free and clear of debris. Cutting Head On each brake job, the technician must center the cutting head for that particular vehicle using one of the mounting bolt holes on the slide plate. Once the head is centered, it is vital that the technician use one hand to push the head firmly and squarely back into the dovetail on the slide plate while using the other hand to tighten the Allen-Hex bolt that secures the head. Failure to do this could result in chatter occurring during the cut. Tool Holder Plate (Cutting Head) The tool holder plate is the plate that the cutting arms are attached to. It can bend or break if a technician accidently runs the cutting arms into the hub of the rotor while the rotor is turning. (Cuts of more than 0.508 mm (0.020 in) can also bend this plate). Once bent, the lathe will most likely not cut properly until the tool holder plate is replaced. In order to verify the condition of the tool holder plate on a machine that will not cut right, remove the mounting bolt and remove the cutting head from the slide plate. With the cutting head titled at an angle, lay the long edge of the tool holder plate down on the flat part of the slide plate. If any gap can be seen between the edge and the slide plate, the tool holder plate is bent and the source of vibration. Also check to ensure that the cutting arms are lying flat on the upper side of the tool holder plate. If the mounting arm post is bent, it will show itself by having the back of the cutting arm lifting off the surface of the tool holder. Gib Adjustment / Loose Gib As wear occurs between the slide plate and the box it rides on, you must take up the slack. You do this by way of a moveable wedge, which we call the gib. Your lathe manual details adjustment process, which you should perform when required after monthly checks or whenever surface finish is inconsistent. Brake Pulsation BRAKE PULSATION Brake pulsation is caused by brake rotor thickness variation. Brake rotor thickness variation causes the piston in the brake caliper, when applied, to "pump" in and out of the caliper housing. The "pumping" effect is transmitted hydraulically to the brake pedal. Brake pulsation concerns may result from two basic conditions: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8880 1. Thickness Variation Pulsation is Caused by Lateral Run Out (LRO). LRO on a brake corner assembly is virtually undetectable unless measured (with a dial indicator after the brake service) and will not be detected as brake pulsation during an after brake service test drive. If the brake corner is assembled with excessive LRO (greater than 0.050 mm (0.002 in), thickness variation will develop on the brake rotor over time and miles. Excessive LRO will cause the brake pads to wear the brake rotors unevenly, which causes rotor thickness variation. Pulsation that is the result of excessive Lateral Run Out usually develops in 4,800-16,000 km (3,000-10,000 mi). The more excessive the LRO, the faster the pulsation will develop. LRO can also be induced when uneven torque is applied to wheel nuts (lug nuts). Improper wheel tightening after tire rotation, spare tire usage, brake inspection, etc. can be the cause of brake pulsation. Again, it usually takes 4,800-16,000 km (3,000-10,000 mi) AFTER the service event for the condition to develop. The customer does not usually make the connection between the service event and the awareness of the pulsation. The proper usage of torque wrenches and/or torque sticks (torque limiting sockets) will greatly reduce or eliminate the pulsation conditions after wheel service events. The improper use of impact wrenches on wheel nuts greatly increases the likelihood of pulsation after wheel service. The following are examples of pulsation conditions and reimbursement recommendations: - If the customer noticed the condition between 4,800-16,000 km (3,000-10,000 mi) and it gradually got worse, normally the repair would be covered. The customer may tolerate the condition until it becomes very apparent. - If a GM dealer performed a prior brake service, consider paying for the repair and then strongly reinforce proper brake lathe maintenance. - If the customer had the brake service done outside of a GM dealership, normally GM would not offer any assistance. - If a customer indicated they had wheel service, ask who performed the service. Then; - If a GM dealer performed the service, consider paying for the repair and then strongly reinforce the use of torque sticks at the dealer. Two common size torque sticks cover 90% of all GM products. Each technician needs to use torque sticks properly every time the wheel nuts are tightened. - If the customer had the wheel service done outside of a GM dealership, normally GM would not offer any assistance. 2. Thickness Variation Pulsation Caused by Brake Rotor Corrosion - Rotor corrosion is another form of thickness variation, which can cause a pulsation concern and can be addressed as follows: - Cosmetic Corrosion: In most instances rotor corrosion is cosmetic and refinishing the rotor is unnecessary. - Corrosion - Pulsation Caused by Thickness Variation (Lot Rot / Low Miles - 0-321 km (0-200 mi): At times more extensive corrosion can cause pulsation due to thickness variation. This usually happens when the vehicle is parked for long periods of time in humid type conditions and the braking surface area under the pads corrodes at a different rate compared to the rest of the braking surface area. Cleaning up of braking surfaces (burnishing) can be accomplished by 10 - 15 moderate stops from 56- 64 km/h (35 - 40 mph) with cooling time between stops. If multiple moderate braking stops do not correct this condition, follow the "Brake Rotor Clean-Up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (without rotor flaking / higher mileage 3,200-8,000 km (2,000-5,000 mi): In some cases, more extensive corrosion that is not cleaned up by the brake pad over time and miles can cause the same type of pulsation complaint due to thickness variation. In these cases, the rotor surface is usually darker instead of shiny and a brake pad foot print can be seen against the darker surface. This darker surface is usually due to build-up, on the rotor material surface, caused by a combination of corrosion, pad material and heat. To correct this condition, follow the "Brake Rotor Clean-up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (with rotor flaking / higher mileage - 8,000 + km (5,000 + miles) : At times, more extensive corrosion over time and miles can cause pulsation due to thickness variation (flaking). This flaking is usually a build up, mostly on the rotor material surface, caused by a combination of corrosion, pad material and heat. When rotor measurements are taken, the low areas are usually close to the original rotor thickness (new rotor) measurement and the high areas usually measure more than the original rotor thickness (new rotor) measurement (depending on mileage and normal wear). To correct this condition, follow the "Brake Rotor Clean-up Procedure" described below. Important In some flaking instances, cleaning-up this type of corrosion may require more rotor material to be removed then desired. Customer consideration should be taken in these situations and handled on a case by case basis, depending on the amount/percentage of rotor life remaining and the vehicle's warranty time and miles. Brake Rotor Clean-Up Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8881 BRAKE ROTOR CLEAN-UP PROCEDURE Clean-up the rotors on an approved, well-maintained brake lathe to guarantee smooth, flat and parallel surfaces. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information see the "Brake Lathe Calibration Procedure" section in this bulletin. 1. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 2. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 3. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 4. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 5. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important In many of these instances, such a minimal amount of material is removed from the rotor that customer satisfaction is not a concern for future brake services. This procedure is intended to "Clean-up" the rotor surface and should be conveyed to the customer as such - not as "cut", "refinish" or "machine", which tends to be terms understood as a substantial reduction of rotor material/life. If the brake lathe equipment being used is not capable of removing minor amounts of material while holding tolerances, further lathe maintenance, repair, updates or equipment replacement may be necessary. Brake Noise BRAKE NOISE Some brake noise is normal and differences in loading, type of driving, or driving style can make a difference in brake wear on the same make and model. Depending on weather conditions, driving patterns and the local environment, brake noise may become more or less apparent. Verify all metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and lubricated with a thin layer of high temperature silicone grease. Brake noise is caused by a "slip-stick" vibration of brake components. While intermittent brake noise may be normal, performing 3 to 4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the noise persists and is consistently occurring, a brake dampening compound may be applied to the back of each pad. This allows parts to slide freely and not vibrate when moving relative to each other. Use Silicone Brake Lubricant, ACDelco P/N 88862181 (Canadian P/N 88862496) or equivalent. The following noises are characteristics of all braking systems and are unavoidable. They may not indicate improper operation of the brake system. Squeak/Squeal Noise: - Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is applied to the brake pedal. - Occasionally a noise may occur on rear brakes during the first few stops or with cold brakes and/or high humidity. Grinding Noise: - Common to rear brakes and some front disc brakes during initial stops after the vehicle has been parked overnight. - Caused by corrosion on the metal surfaces during vehicle non-use. Usually disappears after a few stops. Groan Noise: A groan type noise may be heard when stopping quickly or moving forward slowly from a complete stop. This is normal. On vehicles equipped with ABS, a groan or moan type noise during hard braking applications or loose gravel, wet or icy road conditions is a normal function of the ABS activation. Key Points - Frequently Asked Questions KEY POINTS - FREQUENTLY ASKED QUESTIONS - Q: How do on-car lathes react to Axle Float? Does the play affect the machining of the rotor, either surface finish or LRO? Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8882 A: Because the Pro-Cut on-car lathe adjusts in a live mode while spinning the hub/rotor, the dynamics of a floating axle are effectively eliminated. Once the lathe is compensated, there is no difference in the cutting/surface finish and LRO are just the same as with a non-floating axle. - Q: Which lathe is essential for performing brake work, the bench or on-car? A: Dealers must have a well maintained bench lathe and well maintained on-car lathe. These lathes need to be calibrated on a monthly basis. BOTH lathes are essential to providing quality brake service. - Q: What is the expected tip life for an on-car lathe? A: The geometry and composition of the Pro-Cut tips are designed for "single pass" cutting. When using the Pro-Cut the cutting depth should be set to take all material needed to get below rust grooves, eliminate all run-out and resurface the entire disc in a single pass. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. No "skim cut" or "finish cut" is needed. Failure to follow this procedure will shorten tip life. The Pro-cut tips will last between 7-12 cuts per corner. With three usable corners, a pair of tips is good for at least 21 cuts. - Q: Why does GM recommend the use of single pass (referred to as "positive rake") bench and on-car brake lathes? A: GM Service and GM Brake Engineering have performed competitive evaluations on a significant number of bench and on-car brake lathes. These tests measured critical performance characteristics such as flatness, surface finish and the ability of the lathe to repeat accuracy over many uses. In each test, single pass lathe designs out performed the competitors. Single pass brake lathes are more productive requiring less time to perform the same procedure. - Q: Is it okay to leave the caliper/pads installed while cutting rotors using an on-car lathe? A: On-car lathes should never be used with the pads and calipers installed on the vehicle. The debris from cutting the rotors can contaminate the brake pads/calipers which can lead to other brake concerns and comebacks. - Q: What information needs to be documented on the Repair Order? A: Any claim that is submitted using the labor operations in this bulletin, must have the Original Rotor Thickness and Refinish Rotor Thickness (if refinished) documented on the repair order. For more information, refer to the "Repair Order Required Documentation" section of this bulletin. All Warranty Repair Orders paid by GM, are subject to review for compliance and may be debited where the repair does not comply with this procedure. Brake Warranty BRAKE WARRANTY Brake Rotors: - Brake rotor warranty is covered under the terms of the GM New Vehicle Limited Warranty. Reference the vehicle's warranty guide for verification. - Rotors should not be refinished or replaced during normal/routine pad replacement. - Rotors should not be refinished or replaced and is ineffective in correcting brake squeal type noises and/or premature lining wear out. - Rotors should not be refinished or replaced for cosmetic corrosion. Clean up of braking surfaces can be accomplished by 10-15 moderate stops from 56-64 km/h (35-40 mph) with cooling time between stops. - Rotors should not be refinished or replaced for rotor discoloration/hard spots. - Rotors should be refinished NOT replaced for Customer Pulsation concerns. This condition is a result of rotor thickness variation, usually caused by LRO (wear induced over time and miles) or corrosion (Lot Rot). - When rotor refinishing, only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. - Rotors should be refinished for severe scoring - depth in excess of 1.5 mm (0.060 in). Important If the scoring depth is more than 1.5 mm (0.060 in) after the rotor is refinished, it should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 8883 - It is not necessary to replace rotors in pairs. Rotors may be replaced individually. However, caution should be exercised, as a variance in surface finish may cause a brake pull condition. - New rotors should not be refinished before installation. Original equipment rotor surfaces are ground to ensure smooth finish and parallelism between mounting and friction surfaces. If a new rotor has more than 0.050 mm (0.002 in) Lateral Run Out (LRO) when properly mounted on the hub, correct it using one of the following methods: 1. For hubless rotor designs, use the correction plate procedure found in the "GM Brake Service Procedure for Hubless Rotors" outlined in this bulletin. 2. For hubbed/trapped/captured rotor designs, refinish the rotor using an On-Car lathe and the procedure outlined in this bulletin. - Never reuse rotors that measure under the Minimum Thickness specification. In this instance, the rotor should be replaced. Important If the Minimum Thickness specification is not visible on the rotor, reference Service Information (SI) for the specific vehicle application. DO NOT use any other manufacturers rotor specifications. Brake Pads: Important When determining the warranty coverage (as an example) - if all four front or four rear brake pads are excessively worn evenly, that would NOT be covered under warranty since this type of wear is most likely due to driving habits or trailering. However, if the brake pads are excessively worn un-evenly, side-to-side or same side/inner-to-outer pads, then consideration should be given to cover this under warranty since this type of wear is most likely due to poor operation of other braking components. - Consideration should be given for covering brake pads up to 39,000 km (24,000 mi) (excluding owner abuse, excessive trailering, or the situations that would not be considered normal use). - Installation of new rotors does not require pad replacement. Do not replace pads unless their condition requires it - excessively worn, damage or contaminated. Brake Wear: Several factors impact brake lining wear and should be taken into account when reviewing related issues: - heavy loads / high temperatures / towing / mountainous driving / city driving / aggressive driving / driver braking characteristics (left foot or two feet) The following are conditions that may extend brake lining wear: - light loads / highway driving / conservative driving / level terrain Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 8884 Brake Rotor/Disc: Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 8885 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 8886 JC3/JH1: Brake Vac/Hydraulic Power Disc, 6,400 lbs JC4: Brake Vac Power. Disc, 7,200 lbs JH2: Brake Hydraulic Power, Disc, 7,200 lbs JH6: Brake Hydraulic Power, 4-Wheel Disc, 9,900 lbs JH7: Brake Hydraulic Power, 4-Wheel Disc, 12,300 lbs Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors Brake Rotor/Disc: Service and Repair Burnishing Pads and Rotors Burnishing Pads and Rotors Caution: Refer to Road Test Caution in Service Precautions. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8889 Brake Rotor/Disc: Service and Repair Brake Rotor Replacement - Front Brake Rotor Replacement - Front ^ Tools Required J 41013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Notice: Any new rotor must have the protective coating removed from the friction surfaces before being placed in service. Remove the protective coating using denatured alcohol or an equivalent, and wipe the surface clean with clean cloths. Do not use gasoline, kerosene, or other oil base solvents which may leave an oily residue. This residue is damaging to the brake lining and is flammable. Raise and support the vehicle. Refer Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Remove the front wheel hub extension, dual wheel vehicles only. 1. Insert a drift or large screwdriver through the brake caliper into one of the brake rotor vanes in order to prevent the rotor from turning. 2. Mark the relationship of the front wheel hub extension to the hub. 3. Remove the front wheel hub extension bolts. 4. Remove the front wheel hub extension from the vehicle. It may be necessary to tap around the perimeter of the hub extension with a rubber mallet to loosen it from the hub. 4. Mark the relationship of the rotor to the hub. 5. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8890 6. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads. 7. Remove the C-clamp from the caliper. 8. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper and brake caliper bracket as an assembly and support with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 9. Remove the rotor retaining push nuts from the wheel studs, if applicable. 10. It may be necessary to strike the end of the hub or the rotor with a dead blow hammer to separate the rotor from the hub. 11. Remove the rotor. 12. If the rotor is difficult to remove due to corrosion in the hub area use the following procedure to remove the rotor, 25 and 35 series only. 1. Clean all the surface areas and the threaded holes of contamination. 2. Generously apply penetrating oil or the equivalent to the hub/rotor area. 3. Insert two M10 x 1.5 bolts or jack screws into the threaded holes of the rotor. 4. Tighten both bolts evenly to force the rotor from the hub. Installation Procedure 1. Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. Use the J 42450-A to clean all rust and contaminants from the mating surface of the hub flange. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8891 2. Use the J 41013 to clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Important: If the rotor was removed using the jack screw method you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. Align the rotor to its original position on the hub (if applicable) and install the rotor. 5. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. 6. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout (LRO) Correction. 7. Install the caliper and caliper bracket assembly. 8. Perform the following procedure before installing the brake caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 9. Notice: Refer to Fastener Notice in Service Precautions. Install the caliper bracket mounting bolts. ^ Tighten the brake caliper bracket mounting bolts to 175 Nm (121 ft. lbs.) (15 Series). ^ Tighten the brake caliper bracket mounting bolts to 300 Nm (221 ft. lbs.) (25 and 35 Series). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8892 10. Install the front wheel hub extension (dual wheel vehicles only). 0. Insert a drift or large screwdriver through the brake caliper into one of the brake rotor vanes in order to prevent the rotor from turning. 1. Align and install the front wheel hub extension to the original position on the hub. 2. Important: Follow the same tightening sequence for the front wheel hub extension that is used on an eight lug wheel. Install the front wheel hub extension nuts. ^ Tighten the front wheel hub extension nuts to 130 Nm (96 ft. lbs.). 11. Install the tire and wheel assembly. 12. Lower the vehicle. 13. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 14. Slowly release the brake pedal. 15. Wait 15 seconds, then repeat steps 13-14 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 16. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8893 Brake Rotor/Disc: Service and Repair Brake Rotor Replacement - Rear (Except Dual Wheels or NYS) Brake Rotor Replacement - Rear (Except Dual Wheels or NYS) ^ Tools Required J 2619-01 Slide Hammer With Adapter - J 41013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit - J-46277 Rotor Removal Tool Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Release the park brake. 2. Raise and suitably support the vehicle. Refer Vehicle Lifting 3. Remove the tire and wheel assembly. 4. Mark the relationship of the rotor to the hub. 5. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 6. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads. 7. Remove the C-clamp from the caliper. 8. Remove the brake caliper bracket mounting bolts. 9. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper and brake caliper bracket as an assembly and support with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 10. Remove the rotor retaining push nuts from the wheel studs, if applicable. 11. It may be necessary to strike the end of the hub or the rotor with a dead blow hammer to separate the rotor from the hub. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8894 12. Remove the brake rotor. Do not force the rotor off. If the rotor is difficult to remove, ease it off by gently rotating it as you pull outward. 13. If the brake rotor cannot be removed perform the following: 1. Assemble J-46277 to J 2619-01. 2. Insert J-46277 between the rotor friction surfaces in the vent section of the rotor.DO NOT place the J-46277 on the rotor friction surface. 3. Using J-46277 and J 2619-01 remove the rotor from the hub assembly. 4. Inspect the park brake components for the following conditions: ^ Bent or broken hold down spring ^ Broken, cracked or worn brake shoe lining ^ Bent or damaged brake shoe ^ Worn, bent or damaged backing plate 5. If any of these conditions are found replace the affected parts. Installation Procedure 1. Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. Use the J 42450-A to clean all rust and contaminants from the mating surface of the hub flange. 2. Use the J 41013 to clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Align the rotor to its original position on the hub, if applicable, and install the rotor. 5. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. 6. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8895 Lateral Runout (LRO) Correction. 7. Install the rotor by slowly turning the rotor while pushing the rotor towards the axle. 8. Install the caliper and the bracket as an assembly to the vehicle. 9. Perform the following procedure before installing the caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 10. Notice: Refer to Fastener Notice in Service Precautions. Install the caliper bracket mounting bolts. For the 15 series, tighten the brake caliper bracket mounting bolts to 200 Nm (148 ft. lbs.). For the 25/35 series, tighten the brake caliper bracket mounting bolts to 165 Nm (122 ft. lbs.). 11. Install the tire and wheel assembly. 12. Lower the vehicle. 13. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of it's travel distance. 14. Slowly release the brake pedal. 15. Wait 15 seconds, then repeat steps 13-14 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 16. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. (W/Dual Wheels) Brake Rotor Replacement - Rear (W/Dual Wheels) Caution: Refer to Brake Dust Caution in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8896 Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. Remove the tire and wheel assembly. 4. Remove the hub and rotor assembly. 5. Mark the relationship of the hub to the rotor. 6. Place the hub and rotor assembly on a hydraulic press. 7. Press the wheel studs out of the hub and rotor assembly. Installation Procedure 1. Align the hub and the rotor (if applicable). 2. Install each of the new wheel studs into the hub and rotor assembly by performing the following steps: 1. Install the stud. 2. Install 4 washers to the stud. 3. Install a lug nut to the stud with the flat side of the nut towards the washers. 4. Tighten the lug nut to draw the stud into the hub and rotor assembly. 5. Inspect the hub and rotor assembly to ensure that the hub is tight against the rotor and the stud is seated completely. 6. Remove the lug nut and the washers. 3. Install the hub and rotor assembly to the vehicle. 4. Install the tire and wheel assembly. 5. Lower the vehicle. 6. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of it's travel distance. 7. Slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 6-7 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 9. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8897 (W/NYS) Brake Rotor Replacement - Rear (W/NYS) ^ Tools Required J 41013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Release the park brake. 2. Raise and suitably support the vehicle. Refer Vehicle Lifting 3. Remove the tire and wheel assembly. 4. Mark the relationship of the rotor to the hub. 5. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 6. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads. 7. Remove the C-clamp from the caliper. 8. Remove the nut and the bolt from the quarter shaft shield. 9. Remove the shield. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8898 10. Remove the 2 brake caliper bracket mounting bolts. 11. Mark the relationship of the rotor to the hub. 12. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper and brake caliper mounting bracket as an assembly and support with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 13. Remove the rotor retaining push nuts from the wheel studs, if applicable. 14. It may be necessary to strike the end of the hub or the rotor with a dead blow hammer to separate the rotor from the hub. 15. Remove the rotor by slowly turning the rotor while pulling the rotor away from the axle. Installation Procedure 1. Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. Use the J 42450-A to clean all rust and contaminants from the mating surface of the hub flange. 2. Use the J 41013 to clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Align the rotor to its original position on the hub, if applicable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8899 5. Install the rotor by slowly turning the rotor while pushing the rotor towards the axle. 6. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. 7. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout (LRO) Correction. 8. Install the brake caliper and the brake caliper mounting bracket as an assembly to the vehicle. 9. Perform the following procedure before installing the 2 brake caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolts with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolts. 10. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper bracket mounting bolts. ^ Tighten the brake caliper bracket mounting bolts to 200 Nm (148 ft. lbs.). 11. Install the quarter shaft shield. 12. Install the quarter shaft shield nut and the bolt. ^ Tighten the quarter shaft shield nut and the bolt to 25 Nm (18 ft. lbs.). 13. Install the tire and wheel assembly. 14. Lower the vehicle. 15. With the engine OFF gradually apply the brake pedal to approximately 2/3 of it's travel distance. 16. Slowly release the brake pedal. 17. Wait 15 seconds then repeat steps 15-16 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8900 Brake Rotor/Disc: Service and Repair Disc Brake Splash Shield Replacement - Front Disc Brake Splash Shield Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Remove the hub and bearing assembly. 4. Remove the splash shield (15 series). 5. Remove the splash shield (25/35 series). Installation Procedure 1. Install the splash shield (25/35 series). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8901 2. Install the splash shield (15 series). 3. Install the hub and bearing assembly. 4. Install the tire and wheel assembly. 5. Remove the safety stands. 6. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8902 Brake Rotor/Disc: Service and Repair Burnishing Pads and Rotors Burnishing Pads and Rotors Caution: Refer to Road Test Caution in Service Precautions. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Brake Rotor Replacement - Front Brake Rotor Replacement - Front ^ Tools Required J 41013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Notice: Any new rotor must have the protective coating removed from the friction surfaces before being placed in service. Remove the protective coating using denatured alcohol or an equivalent, and wipe the surface clean with clean cloths. Do not use gasoline, kerosene, or other oil base solvents which may leave an oily residue. This residue is damaging to the brake lining and is flammable. Raise and support the vehicle. Refer Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Remove the front wheel hub extension, dual wheel vehicles only. 1. Insert a drift or large screwdriver through the brake caliper into one of the brake rotor vanes in order to prevent the rotor from turning. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8903 2. Mark the relationship of the front wheel hub extension to the hub. 3. Remove the front wheel hub extension bolts. 4. Remove the front wheel hub extension from the vehicle. It may be necessary to tap around the perimeter of the hub extension with a rubber mallet to loosen it from the hub. 4. Mark the relationship of the rotor to the hub. 5. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 6. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads. 7. Remove the C-clamp from the caliper. 8. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper and brake caliper bracket as an assembly and support with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 9. Remove the rotor retaining push nuts from the wheel studs, if applicable. 10. It may be necessary to strike the end of the hub or the rotor with a dead blow hammer to separate the rotor from the hub. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8904 11. Remove the rotor. 12. If the rotor is difficult to remove due to corrosion in the hub area use the following procedure to remove the rotor, 25 and 35 series only. 1. Clean all the surface areas and the threaded holes of contamination. 2. Generously apply penetrating oil or the equivalent to the hub/rotor area. 3. Insert two M10 x 1.5 bolts or jack screws into the threaded holes of the rotor. 4. Tighten both bolts evenly to force the rotor from the hub. Installation Procedure 1. Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. Use the J 42450-A to clean all rust and contaminants from the mating surface of the hub flange. 2. Use the J 41013 to clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Important: If the rotor was removed using the jack screw method you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor. Align the rotor to its original position on the hub (if applicable) and install the rotor. 5. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. 6. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout (LRO) Correction. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8905 7. Install the caliper and caliper bracket assembly. 8. Perform the following procedure before installing the brake caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 9. Notice: Refer to Fastener Notice in Service Precautions. Install the caliper bracket mounting bolts. ^ Tighten the brake caliper bracket mounting bolts to 175 Nm (121 ft. lbs.) (15 Series). ^ Tighten the brake caliper bracket mounting bolts to 300 Nm (221 ft. lbs.) (25 and 35 Series). 10. Install the front wheel hub extension (dual wheel vehicles only). 0. Insert a drift or large screwdriver through the brake caliper into one of the brake rotor vanes in order to prevent the rotor from turning. 1. Align and install the front wheel hub extension to the original position on the hub. 2. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8906 Follow the same tightening sequence for the front wheel hub extension that is used on an eight lug wheel. Install the front wheel hub extension nuts. ^ Tighten the front wheel hub extension nuts to 130 Nm (96 ft. lbs.). 11. Install the tire and wheel assembly. 12. Lower the vehicle. 13. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 14. Slowly release the brake pedal. 15. Wait 15 seconds, then repeat steps 13-14 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 16. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. (Except Dual Wheels or NYS) Brake Rotor Replacement - Rear (Except Dual Wheels or NYS) ^ Tools Required J 2619-01 Slide Hammer With Adapter - J 41013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit - J-46277 Rotor Removal Tool Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Release the park brake. 2. Raise and suitably support the vehicle. Refer Vehicle Lifting 3. Remove the tire and wheel assembly. 4. Mark the relationship of the rotor to the hub. 5. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 6. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads. 7. Remove the C-clamp from the caliper. 8. Remove the brake caliper bracket mounting bolts. 9. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper and brake caliper bracket as an assembly and support with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 10. Remove the rotor retaining push nuts from the wheel studs, if applicable. 11. It may be necessary to strike the end of the hub or the rotor with a dead blow hammer to separate the rotor from the hub. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8907 12. Remove the brake rotor. Do not force the rotor off. If the rotor is difficult to remove, ease it off by gently rotating it as you pull outward. 13. If the brake rotor cannot be removed perform the following: 1. Assemble J-46277 to J 2619-01. 2. Insert J-46277 between the rotor friction surfaces in the vent section of the rotor.DO NOT place the J-46277 on the rotor friction surface. 3. Using J-46277 and J 2619-01 remove the rotor from the hub assembly. 4. Inspect the park brake components for the following conditions: ^ Bent or broken hold down spring ^ Broken, cracked or worn brake shoe lining ^ Bent or damaged brake shoe ^ Worn, bent or damaged backing plate 5. If any of these conditions are found replace the affected parts. Installation Procedure 1. Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. Use the J 42450-A to clean all rust and contaminants from the mating surface of the hub flange. 2. Use the J 41013 to clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Align the rotor to its original position on the hub, if applicable, and install the rotor. 5. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8908 6. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout (LRO) Correction. 7. Install the rotor by slowly turning the rotor while pushing the rotor towards the axle. 8. Install the caliper and the bracket as an assembly to the vehicle. 9. Perform the following procedure before installing the caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 10. Notice: Refer to Fastener Notice in Service Precautions. Install the caliper bracket mounting bolts. For the 15 series, tighten the brake caliper bracket mounting bolts to 200 Nm (148 ft. lbs.). For the 25/35 series, tighten the brake caliper bracket mounting bolts to 165 Nm (122 ft. lbs.). 11. Install the tire and wheel assembly. 12. Lower the vehicle. 13. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of it's travel distance. 14. Slowly release the brake pedal. 15. Wait 15 seconds, then repeat steps 13-14 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 16. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. (W/Dual Wheels) Brake Rotor Replacement - Rear (W/Dual Wheels) Caution: Refer to Brake Dust Caution in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8909 Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. Remove the tire and wheel assembly. 4. Remove the hub and rotor assembly. 5. Mark the relationship of the hub to the rotor. 6. Place the hub and rotor assembly on a hydraulic press. 7. Press the wheel studs out of the hub and rotor assembly. Installation Procedure 1. Align the hub and the rotor (if applicable). 2. Install each of the new wheel studs into the hub and rotor assembly by performing the following steps: 1. Install the stud. 2. Install 4 washers to the stud. 3. Install a lug nut to the stud with the flat side of the nut towards the washers. 4. Tighten the lug nut to draw the stud into the hub and rotor assembly. 5. Inspect the hub and rotor assembly to ensure that the hub is tight against the rotor and the stud is seated completely. 6. Remove the lug nut and the washers. 3. Install the hub and rotor assembly to the vehicle. 4. Install the tire and wheel assembly. 5. Lower the vehicle. 6. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of it's travel distance. 7. Slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 6-7 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 9. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8910 (W/NYS) Brake Rotor Replacement - Rear (W/NYS) ^ Tools Required J 41013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Release the park brake. 2. Raise and suitably support the vehicle. Refer Vehicle Lifting 3. Remove the tire and wheel assembly. 4. Mark the relationship of the rotor to the hub. 5. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 6. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads. 7. Remove the C-clamp from the caliper. 8. Remove the nut and the bolt from the quarter shaft shield. 9. Remove the shield. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8911 10. Remove the 2 brake caliper bracket mounting bolts. 11. Mark the relationship of the rotor to the hub. 12. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper and brake caliper mounting bracket as an assembly and support with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 13. Remove the rotor retaining push nuts from the wheel studs, if applicable. 14. It may be necessary to strike the end of the hub or the rotor with a dead blow hammer to separate the rotor from the hub. 15. Remove the rotor by slowly turning the rotor while pulling the rotor away from the axle. Installation Procedure 1. Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. Use the J 42450-A to clean all rust and contaminants from the mating surface of the hub flange. 2. Use the J 41013 to clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Align the rotor to its original position on the hub, if applicable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8912 5. Install the rotor by slowly turning the rotor while pushing the rotor towards the axle. 6. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. 7. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout (LRO) Correction. 8. Install the brake caliper and the brake caliper mounting bracket as an assembly to the vehicle. 9. Perform the following procedure before installing the 2 brake caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolts with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolts. 10. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper bracket mounting bolts. ^ Tighten the brake caliper bracket mounting bolts to 200 Nm (148 ft. lbs.). 11. Install the quarter shaft shield. 12. Install the quarter shaft shield nut and the bolt. ^ Tighten the quarter shaft shield nut and the bolt to 25 Nm (18 ft. lbs.). 13. Install the tire and wheel assembly. 14. Lower the vehicle. 15. With the engine OFF gradually apply the brake pedal to approximately 2/3 of it's travel distance. 16. Slowly release the brake pedal. 17. Wait 15 seconds then repeat steps 15-16 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Disc Brake Splash Shield Replacement - Front Disc Brake Splash Shield Replacement - Front Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8913 Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Remove the hub and bearing assembly. 4. Remove the splash shield (15 series). 5. Remove the splash shield (25/35 series). Installation Procedure 1. Install the splash shield (25/35 series). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8914 2. Install the splash shield (15 series). 3. Install the hub and bearing assembly. 4. Install the tire and wheel assembly. 5. Remove the safety stands. 6. Lower the vehicle. Disc Brake Backing Plate Replacement - Rear Disc Brake Backing Plate Replacement - Rear (25/35 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Disable the park brake cable automatic adjuster. Refer to Disabling the Park Brake Cable Automatic Adjuster in Park Brake. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. Remove the tire and wheel assembly. 4. Perform the following procedure to remove the cable (2) from the backing plate (4): 1. Compress the spring (3) by pushing towards the lever (1). 2. Depress the locking tabs. 3. Pull the cable housing out of the backing plate (4). 4. Remove the cable (2) through the slot in the backing plate. 5. Remove the park brake cable (2) from the lever (1). 6. Remove the rotor. 7. Remove the axle shaft. 8. Remove the park brake shoe. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8915 9. Remove the backing plate nuts. 10. Remove the backing plate from the axle housing flange. Installation Procedure 1. Install the backing plate to the axle housing flange. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the backing plate nuts. ^ Tighten the backing plate bolts to 135 Nm (100 ft. lbs.). 3. Install the park brake shoe. 4. Install the axle shaft. 5. Adjust the park brake shoe. Refer to Park Brake Adjustment. 6. Install the rotor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8916 7. Install the park brake cable (2) to the lever (1). 8. Perform the following procedure to install the cable (2) to the backing plate (4): 1. Compress the spring (3) by pushing towards the lever (1). 2. Route the cable (2) through the slot in the backing plate. 3. Push the cable housing into the backing plate (4) until the locking tabs snap into place. 9. Install the tire and wheel assembly. 10. Remove the safety stands. 11. Lower vehicle. 12. Enable the park brake cable automatic adjuster. Refer to Enabling the Park Brake Cable Automatic Adjuster in Park Brake. Brake Rotor Assembled Lateral Runout (LRO) Correction Brake Rotor Assembled Lateral Runout (LRO) Correction Important: ^ Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement. ^ Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11,300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. Review the following acceptable methods for bringing the brake rotor assembled LRO to within specifications. Determine which method to use for the specific vehicle being repaired. ^ Brake Rotor Assembled Lateral Runout (LRO) Correction - Indexing The indexing method of correcting assembled LRO is most effective when the LRO specification is only exceeded by a relatively small amount: 0.025-0.127 mm (0.001-0.005 inch). Indexing is used to achieve the best possible match of high spots to low spots between related components. ^ Brake Rotor Assembled Lateral Runout (LRO) Correction - On-Vehicle Lathe The on-vehicle brake lathe method is used to bring the LRO to within specifications through compensating for LRO while refinishing the brake rotor. If the assembled LRO cannot be corrected using these methods, then other components must be suspected as causing and/or contributing to the LRO concern. Brake Rotor Assembled Lateral Runout (LRO) Correction - Indexing Brake Rotor Assembled Lateral Runout (LRO) Correction - Indexing ^ Tools Required J 39544-KIT Torque-Limiting Socket Set, or equivalent - J 45101-100 Conical Brake Rotor Washers Caution: Refer to Brake Dust Caution in Service Precautions. Important: ^ Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8917 ^ Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. 1. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO measurement procedure. 2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 3. Index the brake rotor in a different orientation to the hub/axle flange. 4. Hold the rotor firmly in place against the hub/axle flange and install one of the J 45101-100 (1) and one lug nut (2) onto the upper-most wheel stud. 5. Continue to hold the rotor secure and tighten the lug nut firmly by hand. 6. Install the remaining J 45101-100 and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. 7. Using the J 39544-KIT , or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. 8. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. 9. Compare the amount of change between this measurement and the original measurement. 10. If this measurement is within specifications, proceed to step 14. 11. If this measurement still exceeds specifications, repeat steps 1-9 until the best assembled LRO measurement is obtained. 12. Matchmark the final location of the rotor to the wheel studs if the orientation is different than it was originally. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8918 13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout (LRO) Correction. 14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the J 45101-100 and the lug nuts. Brake Rotor Assembled Lateral Runout (LRO) Correction - On-Vehicle Lathe Brake Rotor Assembled Lateral Runout (LRO) Correction - On-Vehicle Lathe ^ Tools Required J 45101-100Conical Brake Rotor Washers Caution: Refer to Brake Dust Caution in Service Precautions. Important: ^ Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement. ^ Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11,300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. 1. Ensure that the caliper and caliper bracket that are already being supported, are clear from contacting any rotating components, such as the brake rotor. 2. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure. 3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 4. Set up the lathe, following the manufacturer's instructions. 5. Refinish the brake rotor, following the brake lathe manufacturer's instructions. 6. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement. 7. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. After replacing the rotor, proceed to step 10. 8. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish 2. Using moderate pressure, apply the non-directional finish: ^ If the lathe is equipped with a non-directional finishing tool, apply the finish with 120 grit aluminum oxide sandpaper ^ If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150 grit aluminum oxide sandpaper 3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner 9. Remove the lathe from the vehicle. 10. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. 11. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout (LRO) Correction. 12. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the J 45101-100 and the lug nuts. Brake Rotor Refinishing Brake Rotor Refinishing ^ Tools Required J 41013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit Caution: Refer to Brake Dust Caution in Service Precautions. Important: ^ The disc brake rotors do not require refinishing as part of routine brake system service. New disc brake rotors do not require refinishing.Do not refinish disc brake rotors in an attempt to correct the following conditions: ^ Brake system noise - squeal, growl, groan ^ Uneven and/or premature disc brake pad wear ^ Superficial or cosmetic corrosion/rust of the disc brake rotor friction surface ^ Scoring of the disc brake rotor friction surface less than the maximum allowable specification ^ Before refinishing a brake rotor, the rotor MUST first be checked for adequate thickness to allow the rotor to be refinished and remain above the minimum allowable thickness after refinish specification. Refer to Brake Rotor Thickness Measurement. Disc brake rotors should only be refinished if they have adequate thickness to be refinished and if one or more of the following conditions exist: ^ Thickness variation in excess of the maximum allowable specification ^ Excessive corrosion/rust and/or pitting ^ Cracks and/or heat spots ^ Excessive blueing discoloration ^ Scoring of the disc brake rotor surface in excess of the maximum allowable specification ^ Disc brake rotors may need to be refinished as part of the process for correcting brake rotor assembled lateral runout (LRO) that exceeds the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Burnishing Pads and Rotors > Page 8919 maximum allowable specification. 1. Important: Whenever the brake rotor has been separated from the hub/axle flange, clean any rust or contaminants from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in increased assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. Using the J 42450-A , thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 2. Using the J 41013 , thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Mount the brake rotor to the brake lathe according to the lathe manufacturer's instructions, ensuring that all mounting attachments and adapters are clean and free of debris. 5. Ensure that any vibration dampening attachments are securely in place. 6. With the brake lathe running, slowly bring in the cutting tools until they just contact the brake rotor friction surfaces. 7. Observe the witness mark on the brake rotor. If the witness mark extends approximately three-quarters or more of the way around the brake rotor friction surface on each side, the brake rotor is properly mounted to the lathe. 8. If the witness mark does not extend three-quarters or more of the way around the brake rotor, re-mount the rotor to the lathe. 9. Following the brake lathe manufacturer's instructions, refinish the brake rotor. 10. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement. 11. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. 12. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish 2. Using moderate pressure, apply the non-directional finish: ^ If the lathe is equipped with a non-directional finishing tool, apply the finish with 120 grit aluminum oxide sandpaper ^ If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150 grit aluminum oxide sandpaper 3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner 13. Remove the brake rotor from the brake lathe. 14. Measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. 15. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout (LRO) Correction. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme II Brake Fluid or equivalent DOT-3 brake fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: This procedure may be performed on all vehicles EXCEPT those equipped with option code JL4, Vehicle Stability Enhancement System (VSES). Important: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure) in Hydraulic Brakes before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Depress the brake pedal firmly and maintain steady pressure on the pedal. 4. Using the scan tool, begin the automated bleed procedure. 5. Follow the instructions on the scan tool to complete the automated bleed procedure. Release the brake pedal between each test sequence. 6. Turn the ignition OFF. 7. Remove the scan tool from the vehicle. 8. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11® GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure) in Hydraulic brakes. 10. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 11. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 12. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. Refer to Brake System External Leak Inspection in Hydraulic Brakes. 13. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 14. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes. 15. Drive the vehicle to exceed 13 kph (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 16. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 8931 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition Off and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level.Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 8932 perform the following steps: 1. Inspect the brake system for external leaks. 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 23. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 8933 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) ^ Tools Required J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 35589-A Brake Pressure Bleeder Adapter Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J 35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J 29532 , or equivalent. Add Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J 29532 , or equivalent, to the J 35589-A. 8. Charge the J 29532 , or equivalent, air tank to 175-205 kPa (25-30 psi). 9. Open the J 29532 , or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right front hydraulic circuit install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J 29532 , or equivalent, fluid tank valve, then disconnect the J 29532 , or equivalent, from the J 35589-A. 23. Remove the J 35589-A from the brake master cylinder reservoir. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 8934 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. Refer to ABS Automated Bleed Procedure in Antilock Brake System. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 28. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 8935 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11® (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports.As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up Brake Caliper: Customer Interest Brakes/Wheels - Excessive Debris Build Up Bulletin No.: 04-05-23-005 Date: June 22, 2004 INFORMATION Subject: Availability of Rear Wheel Mud Flaps to Reduce Debris Build-up on Rear Brake Calipers and/or Rear Wheels Models: 1999-2004 Chevrolet Silverado Pickup Models 1999-2004 GMC Sierra Pickup Models This bulletin is to inform dealers of the release of rear wheel mud flaps. The above models that are exposed to extensive off-paved roads may benefit from the mud flaps. The mud flaps have been developed to minimize the amount of stones and/or mud that can impact and collect on the rear caliper and/or wheel rim. Please advise customers that the installation of these mud flaps and following the recommended off-road driving information provided in their Owner's Manual should greatly reduce the possibility of accelerated rear brake component wear and/or rim damage. Install the mud flap forward of each rear wheel using the following procedure. Important: Always work from outboard to inboard, drilling one hole at a time and securing with a fastener. Follow the sequence of the procedure. This will prevent distortion of the mud flap. 1. Raise the vehicle. Support the vehicle. 2. Locate the pickup box side panel rear brace. 3. Remove the existing outboard upper fastener on the brace. 4. Install the mud flap through the "V" of the brace. Install the previously removed fastener in the hole (2) of the mud flap to the brace. Do not tighten the fastener at this time. 5. Using the mud flap as a template, locate and mark the location of the hole (1) in the pickup box wheel house. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up > Page 8944 Important: After drilling the holes, apply the appropriate anti-corrosion primer. Refer to the GM Refinish Material Booklet # 4901 M-D (English) or # 4901-D-F (French) for additional information. 6. Center punch the marked location and drill a 6.35 mm (1/4 in) hole. Install the plastic retainer in the hole (1) of the mud flap. 7. Tighten fastener at the hole (2) location of the mud flap. Tighten Tighten the fastener to 25 N.m (18 lb ft). 8. For vehicles with short box, use the following procedure: 8.1. Push the mud flap to make contact with the rear side of the underbody cross sill and mark the location of the hole (3) of the mud flap. 8.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 8.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 8.4. Repeat the above steps for hole locations 4 and 6. 9. For vehicles with long box, use the following procedure: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up > Page 8945 9.1. Push the mud flap to make contact with the front side of the underbody cross sill and mark location of the hole (5) of the mud flap. 9.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 9.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 9.4. Repeat the above steps for hole location 6. 10. Repeat the above steps for the opposite side. Parts Information Parts are expected to be available from GMSPO on June 30, 2004. Warranty Information Please advise the customer that the mud flaps can be purchased as an accessory. Installation and/or cost of the mud flaps will not be covered under the vehicle's warranty. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 04-05-23-001 > Jan > 04 > Brakes - Low Pedal/Warning Message/Lamp ON Brake Caliper: Customer Interest Brakes - Low Pedal/Warning Message/Lamp ON Bulletin No.: 04-05-23-001 Date: January 21, 2004 TECHNICAL Subject: Low Brake Pedal, Red Brake Light On, Brake System Warning Message On (Tighten Rear Brake Caliper Banjo Bolts, Replace Gaskets and Install Shields) Models: 2000-2004 Chevrolet Silverado 2500 Series 2001-2003 Chevrolet Silverado HD 1500 Series 2001-2004 Chevrolet Suburban 2500 Series 2002-2004 Chevrolet Avalanche 2500 Series 2000-2004 GMC Sierra 2500 Series 2001-2003 GMC Sierra HD 1500 Series 2001-2004 GMC Yukon XL 2500 Series Condition Some customers may comment on a low brake pedal, red brake light on or the brake system warning message is on. Cause Under some extreme off-road conditions, debris may loosen the rear brake caliper banjo bolts causing a brake fluid leak. Correction Follow the service procedure below to inspect the rear brake caliper banjo bolts and gaskets and to install new slide bolts and rear caliper shield. 1. Verify the customer's concern. 2. Open the hood and install fender covers. 3. Clean off the brake master cylinder reservoir with brake clean, P/N 12378392, or equivalent. 4. Visually inspect the brake fluid level through the brake master cylinder reservoir. ^ If the brake warning light is on and the fluid level is low, continue with the next step. ^ If the brake warning light is on and the fluid level is NOT low, continue with Brake Warning Indicator Always On diagnostic. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 6. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheel. 7. Inspect the rear brake calipers for signs of fluid leaks around the banjo bolt area on both rear calipers. 8. Clean off the banjo bolt area with brake clean, P/N 12378392, or equivalent. Important: The banjo bolts copper gasket should not be reused. The banjo bolts may be reused if not damaged. 9. Remove the banjo bolt and discard the copper gaskets. 10. Assemble the two new copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. Important: Inspect both rear caliper banjo bolt torques even if only one side is leaking. Tighten Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 04-05-23-001 > Jan > 04 > Brakes - Low Pedal/Warning Message/Lamp ON > Page 8950 Tighten the bolt to 40 N.m (30 lb ft). Note: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II(R), P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 11. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes. 12. Remove the caliper bracket bolts. 13. Reposition the caliper and bracket on top of the rear leaf spring. 14. Remove the caliper guide pin bolts. 15. Install the two new brake caliper guide pin bolts from the Shield Kit, P/N 15188166. Tighten Tighten the caliper guide pin bolts to 108 N.m (80 lb ft). 16. Install one shield and two nuts from the shield kit. Tighten Tighten the shield retaining nuts to 45 N.m (33 lb ft). 17. Install the caliper and bracket onto the rotor. 18. Install the caliper bracket bolts. Tighten ^ For RPO JH5, tighten the caliper bracket bolts to 200 N.m (148 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 04-05-23-001 > Jan > 04 > Brakes - Low Pedal/Warning Message/Lamp ON > Page 8951 ^ For RPO JH6/JH7, tighten the caliper bracket bolts to 299 N.m (221 lb ft). 19. Repeat this procedure on the opposite side of the vehicle. 20. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 21. Lower the vehicle. 22. Top off the brake fluid reservoir. 23. Remove the fender covers and close the hood. 24. Road test the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 04-05-23-001 > Jan > 04 > Brakes - Low Pedal/Warning Message/Lamp ON > Page 8952 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up Brake Caliper: All Technical Service Bulletins Brakes/Wheels - Excessive Debris Build Up Bulletin No.: 04-05-23-005 Date: June 22, 2004 INFORMATION Subject: Availability of Rear Wheel Mud Flaps to Reduce Debris Build-up on Rear Brake Calipers and/or Rear Wheels Models: 1999-2004 Chevrolet Silverado Pickup Models 1999-2004 GMC Sierra Pickup Models This bulletin is to inform dealers of the release of rear wheel mud flaps. The above models that are exposed to extensive off-paved roads may benefit from the mud flaps. The mud flaps have been developed to minimize the amount of stones and/or mud that can impact and collect on the rear caliper and/or wheel rim. Please advise customers that the installation of these mud flaps and following the recommended off-road driving information provided in their Owner's Manual should greatly reduce the possibility of accelerated rear brake component wear and/or rim damage. Install the mud flap forward of each rear wheel using the following procedure. Important: Always work from outboard to inboard, drilling one hole at a time and securing with a fastener. Follow the sequence of the procedure. This will prevent distortion of the mud flap. 1. Raise the vehicle. Support the vehicle. 2. Locate the pickup box side panel rear brace. 3. Remove the existing outboard upper fastener on the brace. 4. Install the mud flap through the "V" of the brace. Install the previously removed fastener in the hole (2) of the mud flap to the brace. Do not tighten the fastener at this time. 5. Using the mud flap as a template, locate and mark the location of the hole (1) in the pickup box wheel house. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up > Page 8958 Important: After drilling the holes, apply the appropriate anti-corrosion primer. Refer to the GM Refinish Material Booklet # 4901 M-D (English) or # 4901-D-F (French) for additional information. 6. Center punch the marked location and drill a 6.35 mm (1/4 in) hole. Install the plastic retainer in the hole (1) of the mud flap. 7. Tighten fastener at the hole (2) location of the mud flap. Tighten Tighten the fastener to 25 N.m (18 lb ft). 8. For vehicles with short box, use the following procedure: 8.1. Push the mud flap to make contact with the rear side of the underbody cross sill and mark the location of the hole (3) of the mud flap. 8.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 8.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 8.4. Repeat the above steps for hole locations 4 and 6. 9. For vehicles with long box, use the following procedure: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up > Page 8959 9.1. Push the mud flap to make contact with the front side of the underbody cross sill and mark location of the hole (5) of the mud flap. 9.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 9.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 9.4. Repeat the above steps for hole location 6. 10. Repeat the above steps for the opposite side. Parts Information Parts are expected to be available from GMSPO on June 30, 2004. Warranty Information Please advise the customer that the mud flaps can be purchased as an accessory. Installation and/or cost of the mud flaps will not be covered under the vehicle's warranty. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 04-05-23-001 > Jan > 04 > Brakes - Low Pedal/Warning Message/Lamp ON Brake Caliper: All Technical Service Bulletins Brakes - Low Pedal/Warning Message/Lamp ON Bulletin No.: 04-05-23-001 Date: January 21, 2004 TECHNICAL Subject: Low Brake Pedal, Red Brake Light On, Brake System Warning Message On (Tighten Rear Brake Caliper Banjo Bolts, Replace Gaskets and Install Shields) Models: 2000-2004 Chevrolet Silverado 2500 Series 2001-2003 Chevrolet Silverado HD 1500 Series 2001-2004 Chevrolet Suburban 2500 Series 2002-2004 Chevrolet Avalanche 2500 Series 2000-2004 GMC Sierra 2500 Series 2001-2003 GMC Sierra HD 1500 Series 2001-2004 GMC Yukon XL 2500 Series Condition Some customers may comment on a low brake pedal, red brake light on or the brake system warning message is on. Cause Under some extreme off-road conditions, debris may loosen the rear brake caliper banjo bolts causing a brake fluid leak. Correction Follow the service procedure below to inspect the rear brake caliper banjo bolts and gaskets and to install new slide bolts and rear caliper shield. 1. Verify the customer's concern. 2. Open the hood and install fender covers. 3. Clean off the brake master cylinder reservoir with brake clean, P/N 12378392, or equivalent. 4. Visually inspect the brake fluid level through the brake master cylinder reservoir. ^ If the brake warning light is on and the fluid level is low, continue with the next step. ^ If the brake warning light is on and the fluid level is NOT low, continue with Brake Warning Indicator Always On diagnostic. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 6. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheel. 7. Inspect the rear brake calipers for signs of fluid leaks around the banjo bolt area on both rear calipers. 8. Clean off the banjo bolt area with brake clean, P/N 12378392, or equivalent. Important: The banjo bolts copper gasket should not be reused. The banjo bolts may be reused if not damaged. 9. Remove the banjo bolt and discard the copper gaskets. 10. Assemble the two new copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. Important: Inspect both rear caliper banjo bolt torques even if only one side is leaking. Tighten Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 04-05-23-001 > Jan > 04 > Brakes - Low Pedal/Warning Message/Lamp ON > Page 8964 Tighten the bolt to 40 N.m (30 lb ft). Note: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II(R), P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 11. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes. 12. Remove the caliper bracket bolts. 13. Reposition the caliper and bracket on top of the rear leaf spring. 14. Remove the caliper guide pin bolts. 15. Install the two new brake caliper guide pin bolts from the Shield Kit, P/N 15188166. Tighten Tighten the caliper guide pin bolts to 108 N.m (80 lb ft). 16. Install one shield and two nuts from the shield kit. Tighten Tighten the shield retaining nuts to 45 N.m (33 lb ft). 17. Install the caliper and bracket onto the rotor. 18. Install the caliper bracket bolts. Tighten ^ For RPO JH5, tighten the caliper bracket bolts to 200 N.m (148 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 04-05-23-001 > Jan > 04 > Brakes - Low Pedal/Warning Message/Lamp ON > Page 8965 ^ For RPO JH6/JH7, tighten the caliper bracket bolts to 299 N.m (221 lb ft). 19. Repeat this procedure on the opposite side of the vehicle. 20. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 21. Lower the vehicle. 22. Top off the brake fluid reservoir. 23. Remove the fender covers and close the hood. 24. Road test the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 04-05-23-001 > Jan > 04 > Brakes - Low Pedal/Warning Message/Lamp ON > Page 8966 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Page 8967 Brake Caliper: Specifications Brake Caliper Mounting Bolt Front ....................................................................................................................................................... 108 Nm (80 ft. lbs.) Brake Caliper Mounting Bolt Rear (15 series) ......................................................................................................................................... 42 Nm (31 ft. lbs.) Brake Caliper Mounting Bolt Rear (25/35 series) .................................................................................................................................. 108 Nm (80 ft. lbs.) Caliper Mounting Bracket Bolt Rear (JC5/JH5) ................................................................................................................................... 200 Nm (148 ft. lbs.) Caliper Mounting Bracket Bolt Rear (JH6) .......................................................................................................................................... 165 Nm (122 ft. lbs.) Caliper Mounting Bracket Bolt Rear (JH7) .......................................................................................................................................... 300 Nm (221 ft. lbs.) Caliper Mounting Bracket Bolt Rear (NYS) ........................................................................................................................................ 200 Nm (148 ft. lbs.) Caliper Mounting Bracket to Knuckle, Front (15 series) ...................................................................................................................... 175 Nm (129 ft. lbs.) Caliper Mounting Bracket to Knuckle, Front (25/35 series) ................................................................................................................. 300 Nm (221 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front Brake Caliper: Service and Repair Brake Caliper Replacement - Front Brake Caliper Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer Vehicle Lifting 5. Remove the tire and wheel assembly. 6. Compress the brake caliper pistons. ^ Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. ^ Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. ^ Remove the C-clamp from the caliper. 7. Clean all dirt and foreign material from the brake hose end. 8. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. Remove the brake hose to caliper bolt from the brake caliper. 9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. 10. Remove the brake hose from the caliper. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8970 11. Remove the 2 brake caliper mounting bolts. 12. Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result. Remove the brake caliper from the brake caliper mounting bracket. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper to the brake caliper mounting bracket. 2. Install the 2 brake caliper mounting bolts. ^ Tighten the 2 brake caliper mounting bolts to 108 Nm (80 ft. lbs.). 3. Remove the rubber cap or plug from the exposed brake hose fitting end. 4. Important: Install 2 New copper brake hose gaskets. Assemble the 2 New copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. 5. Install the brake hose to caliper bolt to the brake caliper. ^ Tighten the brake hose to caliper bolt to 40 Nm (30 ft. lbs.). 6. Bleed the hydraulic brake system. 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8971 Brake Caliper: Service and Repair Brake Caliper Overhaul - Front Brake Caliper Overhaul - Front ^ Tools Required J 45515 Brake Caliper Piston Boot Seal Installer Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Replace all the components included in the repair kits used to service this brake caliper. 2. Lubricate the rubber parts with new Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid to make assembly easier. 3. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. 4. The torque values specified are for dry, non-lubricated fasteners. 5. Perform the service operations on a clean bench, free from all mineral oil materials. 6. Remove the brake caliper from vehicle. Refer to Brake Caliper Replacement - Front. 7. Drain the brake fluid from the brake caliper. 8. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. Place a 25 mm (1 inch) block of wood between the caliper and the piston. 9. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the block of wood. 10. Carefully remove the brake caliper piston by directing low pressure compressed air into the brake caliper inlet hole. 11. Remove the C-clamp form the caliper. 12. Remove the block of wood from the caliper. 13. Install clean cloths to pad the interior of the caliper housing between the remaining caliper piston and the caliper body. 14. To cover the open caliper bore place a 25 mm (1 inch) block of wood between the caliper body and the brake caliper dust boot seal. 15. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the block of wood. 16. Carefully remove the brake caliper piston by directing low pressure compressed air into the brake caliper inlet hole. 17. Remove the C-clamp form the caliper. 18. Remove the block of wood from the caliper. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8972 19. Important: Care must be used when removing the piston boot and seal from the caliper. Use a small plastic or wood tool for removal. Do not use a metal tool because it may damage the caliper bore or seal groove. Remove the piston boots from the brake caliper. 20. Remove the piston seals from the brake caliper. 21. Remove the brake caliper bleeder valve and cap from the brake caliper. 22. Important: Do not use abrasives to clean the brake caliper piston. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent. 23. Dry the caliper piston bores and counterbores, and the piston with non-lubricated, filtered air. 24. Inspect all of the brake caliper parts as follows. ^ Piston - Inspect for scoring, nicks, cracks, wear, or corrosion. Replace the pistons if any damage is found. ^ Caliper Bore - Inspect for scoring, nicks, cracks, wear, or corrosion. Use crocus cloth to polish out light corrosion. Otherwise, replace the caliper. Do not hone the caliper bore. ^ Seal groove in the caliper bore for nicks or burrs. If found, replace the caliper. 25. Install the brake caliper bleeder valve and bleeder valve cap into the brake caliper. 26. Lubricate the new piston seal with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 10953488) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 27. Install the lubricated, new piston seals into the caliper bores. 28. Install the caliper piston into the caliper bore. 29. Install the new piston dust boot seal over the piston. 30. Using the J 45515 , fully seat the piston dust boot seal in the caliper. 31. Install the brake caliper to the vehicle. Refer to Brake Caliper Replacement - Front. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8973 Brake Caliper: Service and Repair Brake Caliper Replacement - Rear Brake Caliper Replacement - Rear (2500/3500 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer Vehicle Lifting 5. Remove the tire and wheel assembly. 6. Inspect the caliper operation. Refer to Brake Caliper Inspection. 7. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 8. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads. 9. Remove the C-clamp from the caliper. 10. Clean all dirt and foreign material from the brake hose end. 11. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. Remove the brake hose to caliper bolt from the brake caliper. 12. Remove the brake hose from the caliper. 13. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. 14. Loosen the brake caliper mounting bolts. Do not remove. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8974 15. Remove the brake caliper mounting bracket bolts. 16. Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result. Remove the brake caliper and the brake caliper mounting bracket as an assembly. 17. Remove the brake caliper mounting bolts. 18. Remove the brake caliper from the brake caliper mounting bracket. 19. Inspect the caliper assembly. Refer to Brake Caliper Inspection. 20. Remove the brake pads from the brake caliper mounting bracket. 21. Remove the anti-rattle clips from the brake caliper mounting bracket. 22. Inspect the brake caliper mounting bracket for cracks and/or damage. Replace if necessary. 23. Inspect the brake caliper mounting bracket bushings for damage and/or wear. Replace the bushings if necessary. 24. Perform the following procedure to replace the brake caliper mounting bracket bushings. ^ Insert a flat bladed tool between the bushing flange and the mounting bracket. ^ Work the tool around the bushing flange and remove the bushing from the mounting bracket. ^ Place a socket over the boot onto the bushing flange and install the bushing to the mounting bracket. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8975 1. Install the anti-rattle clips to the brake caliper mounting bracket. 2. Install the brake pads to the brake caliper mounting bracket. 3. Install the brake caliper to the brake caliper mounting bracket. 4. Perform the following procedure before installing the brake caliper mounting bracket bolts and the brake caliper mounting bolts: 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 5. Install the brake caliper mounting bolts. Do not tighten. 6. Install the brake caliper mounting bracket and brake caliper as an assembly. 7. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper mounting bracket bolts. ^ Tighten the brake caliper mounting bracket bolts to 300 Nm (221 ft. lbs.). 8. Tighten the brake caliper mounting bolts. ^ Tighten the brake caliper mounting bolts to 108 Nm (80 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8976 9. Remove the rubber cap or plug from the exposed brake hose fitting end. 10. Important: Install 2 new copper brake hose gaskets. Assemble the 2 new copper brake hose gaskets and the brake hose inlet fitting bolt to the brake hose. 11. Connect the brake hose at the caliper by installing the brake hose to caliper bolt. ^ Tighten the bolt to 40 Nm (30 ft. lbs.). 12. Bleed the hydraulic brake system. 13. Install the tire and wheel assembly. 14. Lower the vehicle. 15. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8977 Brake Caliper: Service and Repair Brake Caliper Overhaul - Rear Brake Caliper Overhaul - Rear (25/35 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Disassembly Procedure Important: ^ Replace all the components included in the repair kits used to service this brake caliper. ^ Lubricate the rubber parts with clean brake fluid to make assembly easier. ^ The torque values specified are for dry, non lubricated fasteners. ^ Perform the service operations on a clean bench, free from all mineral oil materials. 1. Remove the brake caliper from the vehicle. 2. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Place a thin piece wood in front of the pistons in order to prevent damage. Remove the pistons by directing compressed air into the brake hose inlet fitting port of the brake caliper housing. 3. Remove the 2 pistons. 4. Remove the 2 piston boots. 5. Remove the 2 piston seals. 6. Remove the brake caliper bleed screw cap. 7. Remove the brake caliper bleed screw. 8. Inspect the brake caliper bores and the piston seal grooves for scoring and corrosion. If you find excessive scoring or corrosion around the 2 piston seal areas replace the brake caliper housing. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8978 9. Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and replace the brake caliper mounting bracket if needed. 10. Clean all the residue from the brake pad guiding surfaces on the brake caliper housing and the brake caliper mounting bracket. 11. Clean all the parts not included in the repair kit with denatured alcohol. 12. Dry all the parts with non lubricated filtered compressed air. 13. Blow out all passages in the brake caliper housing and the brake caliper bleeder valve. Assembly Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper bleed screw. ^ Tighten the brake caliper bleed screw to 12 Nm (106 inch lbs.). 2. Install the brake caliper bleed screw cap. 3. Lubricate the new piston seal and the brake caliper bore seal groove with brake fluid. 4. Install new the seal into the brake caliper bore seal groove. 5. Ensure that the seal is not twisted. 6. Lubricate the brake caliper bore and the piston with brake fluid. 7. Install the boot and the piston. 1. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. 2. Seat the boot into the brake caliper bore groove. Slide the piston into the brake caliper bore. 3. Push down the piston to the bottom of the brake caliper bore. 4. Ensure that the boot properly seats into the piston groove and into the groove in the brake caliper bore. 5. Repeat steps 5 and 6 for the remaining piston. 8. Install the brake caliper to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8979 Brake Caliper: Service and Repair Brake Caliper Replacement - Front Brake Caliper Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer Vehicle Lifting 5. Remove the tire and wheel assembly. 6. Compress the brake caliper pistons. ^ Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. ^ Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. ^ Remove the C-clamp from the caliper. 7. Clean all dirt and foreign material from the brake hose end. 8. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. Remove the brake hose to caliper bolt from the brake caliper. 9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. 10. Remove the brake hose from the caliper. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8980 11. Remove the 2 brake caliper mounting bolts. 12. Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result. Remove the brake caliper from the brake caliper mounting bracket. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper to the brake caliper mounting bracket. 2. Install the 2 brake caliper mounting bolts. ^ Tighten the 2 brake caliper mounting bolts to 108 Nm (80 ft. lbs.). 3. Remove the rubber cap or plug from the exposed brake hose fitting end. 4. Important: Install 2 New copper brake hose gaskets. Assemble the 2 New copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. 5. Install the brake hose to caliper bolt to the brake caliper. ^ Tighten the brake hose to caliper bolt to 40 Nm (30 ft. lbs.). 6. Bleed the hydraulic brake system. 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8981 Brake Caliper Overhaul - Front Brake Caliper Overhaul - Front ^ Tools Required J 45515 Brake Caliper Piston Boot Seal Installer Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Replace all the components included in the repair kits used to service this brake caliper. 2. Lubricate the rubber parts with new Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid to make assembly easier. 3. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. 4. The torque values specified are for dry, non-lubricated fasteners. 5. Perform the service operations on a clean bench, free from all mineral oil materials. 6. Remove the brake caliper from vehicle. Refer to Brake Caliper Replacement - Front. 7. Drain the brake fluid from the brake caliper. 8. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. Place a 25 mm (1 inch) block of wood between the caliper and the piston. 9. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the block of wood. 10. Carefully remove the brake caliper piston by directing low pressure compressed air into the brake caliper inlet hole. 11. Remove the C-clamp form the caliper. 12. Remove the block of wood from the caliper. 13. Install clean cloths to pad the interior of the caliper housing between the remaining caliper piston and the caliper body. 14. To cover the open caliper bore place a 25 mm (1 inch) block of wood between the caliper body and the brake caliper dust boot seal. 15. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the block of wood. 16. Carefully remove the brake caliper piston by directing low pressure compressed air into the brake caliper inlet hole. 17. Remove the C-clamp form the caliper. 18. Remove the block of wood from the caliper. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8982 19. Important: Care must be used when removing the piston boot and seal from the caliper. Use a small plastic or wood tool for removal. Do not use a metal tool because it may damage the caliper bore or seal groove. Remove the piston boots from the brake caliper. 20. Remove the piston seals from the brake caliper. 21. Remove the brake caliper bleeder valve and cap from the brake caliper. 22. Important: Do not use abrasives to clean the brake caliper piston. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent. 23. Dry the caliper piston bores and counterbores, and the piston with non-lubricated, filtered air. 24. Inspect all of the brake caliper parts as follows. ^ Piston - Inspect for scoring, nicks, cracks, wear, or corrosion. Replace the pistons if any damage is found. ^ Caliper Bore - Inspect for scoring, nicks, cracks, wear, or corrosion. Use crocus cloth to polish out light corrosion. Otherwise, replace the caliper. Do not hone the caliper bore. ^ Seal groove in the caliper bore for nicks or burrs. If found, replace the caliper. 25. Install the brake caliper bleeder valve and bleeder valve cap into the brake caliper. 26. Lubricate the new piston seal with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 10953488) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 27. Install the lubricated, new piston seals into the caliper bores. 28. Install the caliper piston into the caliper bore. 29. Install the new piston dust boot seal over the piston. 30. Using the J 45515 , fully seat the piston dust boot seal in the caliper. 31. Install the brake caliper to the vehicle. Refer to Brake Caliper Replacement - Front. Brake Caliper Replacement - Rear Brake Caliper Replacement - Rear (2500/3500 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8983 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer Vehicle Lifting 5. Remove the tire and wheel assembly. 6. Inspect the caliper operation. Refer to Brake Caliper Inspection. 7. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 8. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads. 9. Remove the C-clamp from the caliper. 10. Clean all dirt and foreign material from the brake hose end. 11. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. Remove the brake hose to caliper bolt from the brake caliper. 12. Remove the brake hose from the caliper. 13. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. 14. Loosen the brake caliper mounting bolts. Do not remove. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8984 15. Remove the brake caliper mounting bracket bolts. 16. Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result. Remove the brake caliper and the brake caliper mounting bracket as an assembly. 17. Remove the brake caliper mounting bolts. 18. Remove the brake caliper from the brake caliper mounting bracket. 19. Inspect the caliper assembly. Refer to Brake Caliper Inspection. 20. Remove the brake pads from the brake caliper mounting bracket. 21. Remove the anti-rattle clips from the brake caliper mounting bracket. 22. Inspect the brake caliper mounting bracket for cracks and/or damage. Replace if necessary. 23. Inspect the brake caliper mounting bracket bushings for damage and/or wear. Replace the bushings if necessary. 24. Perform the following procedure to replace the brake caliper mounting bracket bushings. ^ Insert a flat bladed tool between the bushing flange and the mounting bracket. ^ Work the tool around the bushing flange and remove the bushing from the mounting bracket. ^ Place a socket over the boot onto the bushing flange and install the bushing to the mounting bracket. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8985 1. Install the anti-rattle clips to the brake caliper mounting bracket. 2. Install the brake pads to the brake caliper mounting bracket. 3. Install the brake caliper to the brake caliper mounting bracket. 4. Perform the following procedure before installing the brake caliper mounting bracket bolts and the brake caliper mounting bolts: 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 5. Install the brake caliper mounting bolts. Do not tighten. 6. Install the brake caliper mounting bracket and brake caliper as an assembly. 7. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper mounting bracket bolts. ^ Tighten the brake caliper mounting bracket bolts to 300 Nm (221 ft. lbs.). 8. Tighten the brake caliper mounting bolts. ^ Tighten the brake caliper mounting bolts to 108 Nm (80 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8986 9. Remove the rubber cap or plug from the exposed brake hose fitting end. 10. Important: Install 2 new copper brake hose gaskets. Assemble the 2 new copper brake hose gaskets and the brake hose inlet fitting bolt to the brake hose. 11. Connect the brake hose at the caliper by installing the brake hose to caliper bolt. ^ Tighten the bolt to 40 Nm (30 ft. lbs.). 12. Bleed the hydraulic brake system. 13. Install the tire and wheel assembly. 14. Lower the vehicle. 15. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes. Brake Caliper Overhaul - Rear Brake Caliper Overhaul - Rear (25/35 Series) Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Disassembly Procedure Important: ^ Replace all the components included in the repair kits used to service this brake caliper. ^ Lubricate the rubber parts with clean brake fluid to make assembly easier. ^ The torque values specified are for dry, non lubricated fasteners. ^ Perform the service operations on a clean bench, free from all mineral oil materials. 1. Remove the brake caliper from the vehicle. 2. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Place a thin piece wood in front of the pistons in order to prevent damage. Remove the pistons by directing compressed air into the brake hose inlet fitting port of the brake caliper housing. 3. Remove the 2 pistons. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8987 4. Remove the 2 piston boots. 5. Remove the 2 piston seals. 6. Remove the brake caliper bleed screw cap. 7. Remove the brake caliper bleed screw. 8. Inspect the brake caliper bores and the piston seal grooves for scoring and corrosion. If you find excessive scoring or corrosion around the 2 piston seal areas replace the brake caliper housing. 9. Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and replace the brake caliper mounting bracket if needed. 10. Clean all the residue from the brake pad guiding surfaces on the brake caliper housing and the brake caliper mounting bracket. 11. Clean all the parts not included in the repair kit with denatured alcohol. 12. Dry all the parts with non lubricated filtered compressed air. 13. Blow out all passages in the brake caliper housing and the brake caliper bleeder valve. Assembly Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the brake caliper bleed screw. ^ Tighten the brake caliper bleed screw to 12 Nm (106 inch lbs.). 2. Install the brake caliper bleed screw cap. 3. Lubricate the new piston seal and the brake caliper bore seal groove with brake fluid. 4. Install new the seal into the brake caliper bore seal groove. 5. Ensure that the seal is not twisted. 6. Lubricate the brake caliper bore and the piston with brake fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8988 7. Install the boot and the piston. 1. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. 2. Seat the boot into the brake caliper bore groove. Slide the piston into the brake caliper bore. 3. Push down the piston to the bottom of the brake caliper bore. 4. Ensure that the boot properly seats into the piston groove and into the groove in the brake caliper bore. 5. Repeat steps 5 and 6 for the remaining piston. 8. Install the brake caliper to the vehicle. Brake Caliper Bracket Replacement - Front Brake Caliper Bracket Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. Refer to Brake Caliper Replacement Front. 2. Remove the brake pads. 3. Remove the anti-rattle clips from the brake caliper bracket. 4. Remove the brake caliper bracket mounting bolts (2). 5. Remove the brake caliper bracket (1). 6. Remove any contaminants or foreign material from the inside ends of the brake caliper bracket. 7. Clean the mounting surface and threads of the brake caliper bracket. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8989 1. Install the brake caliper bracket (1). 2. Perform the following procedure before installing the brake caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the caliper bracket mounting bolts (2). ^ Tighten the brake caliper bracket mounting bolts to 175 Nm (121 ft. lbs.) (15 Series). ^ Tighten the brake caliper bracket mounting bolts to 300 Nm (221 ft. lbs.) (25 and 35 Series). 4. Install the anti-rattle clips to the brake caliper bracket. 5. Install the brake pads to the brake caliper bracket. 6. Slide the brake pads in until they contact the rotor. 7. Install the brake caliper. Refer to Brake Caliper Replacement - Front. 8. Install the tire and wheel assembly. 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of it's travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 10-11 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Brake Caliper Bracket Replacement - Rear Brake Caliper Bracket Replacement - Rear (15/25 Series w/o NYS) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper from the brake caliper mounting bracket and support the brake caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake hose from the brake caliper. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8990 4. Remove the brake pads from the brake caliper mounting bracket. 5. Remove the anti-rattle clips from the brake caliper bracket. 6. Remove the brake caliper bracket mounting bolts (2). 7. Remove the brake caliper bracket (1). 8. Remove any contaminants or foreign material from the inside ends of the brake caliper bracket. 9. Clean the mounting surface and threads of the brake caliper bracket. Installation Procedure 1. Install the brake caliper bracket (1). 2. Perform the following procedure before installing the brake caliper bracket mounting bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the caliper bracket mounting bolts (2). For vehicles equipped with JH5 brake systems, tighten the caliper bracket mounting bolts to 200 Nm (148 ft. lbs.). For vehicles equipped with JH6/JH7 brake systems, tighten the caliper bracket mounting bolts to 300 Nm (221 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8991 4. Install the anti-rattle clips to the brake caliper mounting bracket. 5. Install the brake pads to the brake caliper mounting bracket. 6. Slide the brake pads in until they contact the rotor. 7. Install the brake caliper. 8. Install the tire and wheel assembly. 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of it's travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 10-11 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Disc Brake Hardware Replacement - Front Disc Brake Hardware Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer Vehicle Lifting 2. Remove the tire and wheel assembly. 3. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. Refer to Brake Caliper Replacement Front. 4. Remove the disc brake pads from the disc brake caliper mounting bracket. 5. Remove the disc brake pad retainers from the disc brake caliper mounting bracket. 6. Inspect the disc brake hardware. Refer to Disc Brake Mounting and Hardware Inspection - Front. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8992 7. Remove the caliper pin boots (4) from the disc brake caliper mounting bracket (3). Installation Procedure 1. Lubricate the front brake caliper bushings, bolts and seals with high temperature silicone brake lubricant. 2. Install the caliper pin boots (4) to the disc brake caliper mounting bracket (3). 3. Install the disc brake pad retainers to the disc brake caliper mounting bracket. 4. Install the disc brake pads to the disc brake caliper mounting bracket. 5. Install the disc brake caliper to the caliper mounting bracket. Refer to Brake Caliper Replacement - Front. 6. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance. 7. Slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 6-7 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. Disc Brake Hardware Replacement - Rear Disc Brake Hardware Replacement - Rear Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer Vehicle Lifting 2. Remove the tire and wheel assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Replacement - Front > Page 8993 3. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Remove the brake caliper from the brake caliper mounting bracket and support the brake caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake hose from the caliper. 4. Remove the disc brake pads from the brake caliper mounting bracket. 5. Remove the disc brake pad retainers from the brake caliper mounting bracket. 6. Remove the caliper slide pins (5) from the brake caliper mounting bracket (3). 7. Remove the caliper slide pin boots (4) from the brake caliper mounting bracket. 8. Inspect the disc brake hardware. Installation Procedure 1. Lubricate the brake caliper mounting bracket bushings and the caliper slide pins with high temperature silicone brake lubricant. 2. Install the caliper slide pin boots (4) to the disc brake caliper mounting bracket. 3. Install the caliper slide pins (5) to the brake caliper mounting bracket (3). 4. Install the disc brake pad retainers to the brake caliper mounting bracket. 5. Install the disc brake pads to the brake caliper mounting bracket. 6. Install the disc brake caliper to the brake caliper mounting bracket. 7. With the engine OFF, gradually apply the brake pedal approximately 2/3 of it's travel distance. 8. Slowly release the brake pedal. 9. Wait 15 seconds, then repeat steps 7-8 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 10. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Capacity Specifications Brake Fluid: Capacity Specifications Information not supplied by the manufacturer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Capacity Specifications > Page 8998 Brake Fluid: Fluid Type Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme II Brake Fluid or equivalent DOT-3 brake fluid. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-23-001 > Jan > 04 > Brakes - Low Pedal/Warning Message/Lamp ON Brake Hose/Line: Customer Interest Brakes - Low Pedal/Warning Message/Lamp ON Bulletin No.: 04-05-23-001 Date: January 21, 2004 TECHNICAL Subject: Low Brake Pedal, Red Brake Light On, Brake System Warning Message On (Tighten Rear Brake Caliper Banjo Bolts, Replace Gaskets and Install Shields) Models: 2000-2004 Chevrolet Silverado 2500 Series 2001-2003 Chevrolet Silverado HD 1500 Series 2001-2004 Chevrolet Suburban 2500 Series 2002-2004 Chevrolet Avalanche 2500 Series 2000-2004 GMC Sierra 2500 Series 2001-2003 GMC Sierra HD 1500 Series 2001-2004 GMC Yukon XL 2500 Series Condition Some customers may comment on a low brake pedal, red brake light on or the brake system warning message is on. Cause Under some extreme off-road conditions, debris may loosen the rear brake caliper banjo bolts causing a brake fluid leak. Correction Follow the service procedure below to inspect the rear brake caliper banjo bolts and gaskets and to install new slide bolts and rear caliper shield. 1. Verify the customer's concern. 2. Open the hood and install fender covers. 3. Clean off the brake master cylinder reservoir with brake clean, P/N 12378392, or equivalent. 4. Visually inspect the brake fluid level through the brake master cylinder reservoir. ^ If the brake warning light is on and the fluid level is low, continue with the next step. ^ If the brake warning light is on and the fluid level is NOT low, continue with Brake Warning Indicator Always On diagnostic. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 6. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheel. 7. Inspect the rear brake calipers for signs of fluid leaks around the banjo bolt area on both rear calipers. 8. Clean off the banjo bolt area with brake clean, P/N 12378392, or equivalent. Important: The banjo bolts copper gasket should not be reused. The banjo bolts may be reused if not damaged. 9. Remove the banjo bolt and discard the copper gaskets. 10. Assemble the two new copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. Important: Inspect both rear caliper banjo bolt torques even if only one side is leaking. Tighten Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-23-001 > Jan > 04 > Brakes - Low Pedal/Warning Message/Lamp ON > Page 9007 Tighten the bolt to 40 N.m (30 lb ft). Note: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II(R), P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 11. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes. 12. Remove the caliper bracket bolts. 13. Reposition the caliper and bracket on top of the rear leaf spring. 14. Remove the caliper guide pin bolts. 15. Install the two new brake caliper guide pin bolts from the Shield Kit, P/N 15188166. Tighten Tighten the caliper guide pin bolts to 108 N.m (80 lb ft). 16. Install one shield and two nuts from the shield kit. Tighten Tighten the shield retaining nuts to 45 N.m (33 lb ft). 17. Install the caliper and bracket onto the rotor. 18. Install the caliper bracket bolts. Tighten ^ For RPO JH5, tighten the caliper bracket bolts to 200 N.m (148 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-23-001 > Jan > 04 > Brakes - Low Pedal/Warning Message/Lamp ON > Page 9008 ^ For RPO JH6/JH7, tighten the caliper bracket bolts to 299 N.m (221 lb ft). 19. Repeat this procedure on the opposite side of the vehicle. 20. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 21. Lower the vehicle. 22. Top off the brake fluid reservoir. 23. Remove the fender covers and close the hood. 24. Road test the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-23-001 > Jan > 04 > Brakes - Low Pedal/Warning Message/Lamp ON > Page 9009 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-05-23-001 > Jan > 04 > Brakes - Low Pedal/Warning Message/Lamp ON Brake Hose/Line: All Technical Service Bulletins Brakes - Low Pedal/Warning Message/Lamp ON Bulletin No.: 04-05-23-001 Date: January 21, 2004 TECHNICAL Subject: Low Brake Pedal, Red Brake Light On, Brake System Warning Message On (Tighten Rear Brake Caliper Banjo Bolts, Replace Gaskets and Install Shields) Models: 2000-2004 Chevrolet Silverado 2500 Series 2001-2003 Chevrolet Silverado HD 1500 Series 2001-2004 Chevrolet Suburban 2500 Series 2002-2004 Chevrolet Avalanche 2500 Series 2000-2004 GMC Sierra 2500 Series 2001-2003 GMC Sierra HD 1500 Series 2001-2004 GMC Yukon XL 2500 Series Condition Some customers may comment on a low brake pedal, red brake light on or the brake system warning message is on. Cause Under some extreme off-road conditions, debris may loosen the rear brake caliper banjo bolts causing a brake fluid leak. Correction Follow the service procedure below to inspect the rear brake caliper banjo bolts and gaskets and to install new slide bolts and rear caliper shield. 1. Verify the customer's concern. 2. Open the hood and install fender covers. 3. Clean off the brake master cylinder reservoir with brake clean, P/N 12378392, or equivalent. 4. Visually inspect the brake fluid level through the brake master cylinder reservoir. ^ If the brake warning light is on and the fluid level is low, continue with the next step. ^ If the brake warning light is on and the fluid level is NOT low, continue with Brake Warning Indicator Always On diagnostic. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 6. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheel. 7. Inspect the rear brake calipers for signs of fluid leaks around the banjo bolt area on both rear calipers. 8. Clean off the banjo bolt area with brake clean, P/N 12378392, or equivalent. Important: The banjo bolts copper gasket should not be reused. The banjo bolts may be reused if not damaged. 9. Remove the banjo bolt and discard the copper gaskets. 10. Assemble the two new copper brake hose gaskets and the brake hose to caliper bolt to the brake hose. Important: Inspect both rear caliper banjo bolt torques even if only one side is leaking. Tighten Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-05-23-001 > Jan > 04 > Brakes - Low Pedal/Warning Message/Lamp ON > Page 9015 Tighten the bolt to 40 N.m (30 lb ft). Note: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II(R), P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 11. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes. 12. Remove the caliper bracket bolts. 13. Reposition the caliper and bracket on top of the rear leaf spring. 14. Remove the caliper guide pin bolts. 15. Install the two new brake caliper guide pin bolts from the Shield Kit, P/N 15188166. Tighten Tighten the caliper guide pin bolts to 108 N.m (80 lb ft). 16. Install one shield and two nuts from the shield kit. Tighten Tighten the shield retaining nuts to 45 N.m (33 lb ft). 17. Install the caliper and bracket onto the rotor. 18. Install the caliper bracket bolts. Tighten ^ For RPO JH5, tighten the caliper bracket bolts to 200 N.m (148 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-05-23-001 > Jan > 04 > Brakes - Low Pedal/Warning Message/Lamp ON > Page 9016 ^ For RPO JH6/JH7, tighten the caliper bracket bolts to 299 N.m (221 lb ft). 19. Repeat this procedure on the opposite side of the vehicle. 20. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 21. Lower the vehicle. 22. Top off the brake fluid reservoir. 23. Remove the fender covers and close the hood. 24. Road test the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-05-23-001 > Jan > 04 > Brakes - Low Pedal/Warning Message/Lamp ON > Page 9017 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Hose/Line: > 04-08-52-005 > Jun > 04 > Keyless Entry - Inoperative Keyless Entry Module: All Technical Service Bulletins Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Hose/Line: > 04-08-52-005 > Jun > 04 > Keyless Entry - Inoperative > Page 9023 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Hose/Line: > 04-08-52-005 > Jun > 04 > Keyless Entry - Inoperative > Page 9029 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement Brake Hose/Line: Service and Repair Brake Pipe Replacement Brake Pipe Replacement Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Caution: Always use double-walled steel brake pipe when replacing brake pipes. The use of any other pipe is not recommended and may cause brake system failure. Carefully route and retain replacement brake pipes. Always use the correct fasteners and in the original location for replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes and brake system resulting in personal injury. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: Brake pipes that run parallel to each other must maintain a 6 mm (1/4 inch) clearance. 1. Disconnect the brake pipe fittings. 2. Remove the brake pipe fasteners from the vehicle. 3. Remove the brake pipe from the vehicle. Installation Procedure 1. Bend the brake pipe to achieve proper fit. 2. Install the brake pipe to the vehicle. Maintain a clearance of 19 mm (3/4 inch) for all moving or vibrating components. 3. Install the brake pipe fasteners to the vehicle. 4. Notice: Refer to Fastener Notice in Service Precautions. Connect the brake pipe fittings. ^ Tighten the brake pipe fittings to the brake pressure modulator valve (BPMV) or the wheel jounce hoses to 25 Nm (18 ft. lbs.). ^ Tighten the brake pipe fittings to the master cylinder to 25 Nm (18 ft. lbs.). 5. Bleed the hydraulic brake system. Refer to ABS Automated Bleed Procedure in Antilock Brake System. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9032 Brake Hose/Line: Service and Repair Brake Hose Replacement - Front Brake Hose Replacement - Front Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Raise and suitably support the vehicle. 2. Remove the tire and wheel assembly. 3. Clean all dirt and foreign material from the brake hose and brake pipe fittings. 4. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Use a backup wrench on the hose fitting, disconnect the brake pipe fitting from the brake hose, then cap or plug the brake pipe fitting end. 5. Remove the brake hose retaining clip from the hose mounting bracket. 6. Remove the brake hose bolt and the bracket from the upper control arm. 7. Remove the brake hose bolt and the bracket from the steering knuckle. 8. Remove the brake hose to caliper bolt from the brake caliper. 9. Remove the brake hose from the brake caliper. 10. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9033 1. Important: Install 2 new copper brake hose gaskets. Assemble the 2 new copper brake hose gaskets, and the brake hose bolt to the brake hose. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the brake hose to caliper bolt and 2 new washers to the brake caliper. ^ Tighten the bolt to 40 Nm (30 ft. lbs.). 3. Important: The hose must not be twisted. Make sure the hose is not in contact with any suspension component. With the weight of the vehicle on the suspension, install the brake hose into the bracket. 4. Install the brake hose bolt and the bracket to the steering knuckle. ^ Tighten the bolt to 9 Nm (80 inch lbs.). 5. Install the brake hose bolt and the bracket to the upper control arm. ^ Tighten the bolt to 9 Nm (80 inch lbs.). 6. Install the brake hose retaining clip. 7. Remove the rubber cap or plug from the exposed brake pipe fitting end. 8. Connect the brake pipe fitting nut to the brake hose: ^ Use a backup wrench on the hose fitting. ^ Do not bend the bracket or the pipe. ^ Tighten the bolt to 25 Nm (18 ft. lbs.). 9. Bleed the hydraulic brake system. 10. Install the tire and wheel assembly. 11. Ensure that the hose does not make contact with any part of the suspension or the wheel. Check the hose in extreme right and left turn conditions. If the hose makes contact, remove the hose and correct the condition. 12. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9034 Brake Hose/Line: Service and Repair Brake Hose Replacement - Rear (Caliper) Brake Hose Replacement - Rear (Caliper) Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Raise and suitably support the vehicle. 2. Remove the tire and wheel assembly. 3. Clean all dirt and foreign material from the brake hose and brake pipe fittings. 4. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Use a backup wrench on the hose fitting end (1), disconnect the brake pipe fitting (2) from the brake hose (1), then cap or plug the brake pipe fitting end. 5. Remove the brake hose retaining clip (3) from the hose mounting bracket. 6. Remove the brake hose (1) from the mounting bracket. 7. Remove the brake hose to caliper bolt from the brake caliper. 8. Remove the brake hose from the brake caliper. 9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9035 1. Important: Install 2 new copper brake hose gaskets. Assemble the 2 new copper brake hose gaskets and the brake hose bolt to the brake hose. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the brake hose to caliper bolt and 2 new washers to the brake caliper. ^ Tighten the bolt to 40 Nm (30 ft. lbs.). 3. Important: The hose must not be twisted. Make sure the hose is not in contact with any suspension component. Install the brake hose (1) into the brake hose bracket. 4. Install the brake hose retaining clip (3). 5. Remove the rubber cap or plug from the exposed brake pipe fitting end. 6. Connect the brake pipe fitting nut (2) to the brake hose (1): ^ Use a backup wrench on the hose fitting (1). ^ Do not bend the bracket or the pipe. ^ Tighten the brake pipe fitting end (2) to 25 Nm (18 ft. lbs.). 7. Bleed the hydraulic brake system. 8. Install the tire and wheel assembly. 9. Ensure that the hose does not make contact with any part of the suspension or the wheel. If the hose makes contact remove the hose and correct the condition. 10. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9036 Brake Hose/Line: Service and Repair Brake Hose Replacement - Rear (Jounce) Brake Hose Replacement - Rear (Jounce) Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Raise and support the vehicle. 2. Clean all dirt and foreign material from the brake hose and brake pipe fittings. 3. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Use a backup wrench on the hose fitting, disconnect the brake pipe fitting from the brake hose, then cap or plug the brake pipe fitting end. 4. Remove the brake hose retaining clip from the hose mounting bracket. 5. Remove the jounce hose from the bracket. 6. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Disconnect the rear brake pipes from the junction block on the rear axle and cap or plug the brake pipe fitting ends. 7. Remove the junction block retaining bolt from the axle. 8. Remove the brake hose from the vehicle. Installation Procedure 1. Install the rear brake hose 2. Notice: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9037 Refer to Fastener Notice in Service Precautions. Install the junction block retaining bolt to the axle. ^ Tighten the bolt to 22 Nm (16 ft. lbs.). 3. Uncap or unplug the rear brake pipes and connect the pipes to the junction block on the axle. ^ Tighten the fitting to 25 Nm (18 ft. lbs.). 4. Important: The hose must not be twisted. Make sure the hose is not in contact with any suspension component. Install the brake hose into the bracket. 5. Install the jounce hose retaining clip. 6. Remove the rubber cap or plug from the exposed brake pipe fitting end. 7. Connect the brake pipe fitting nut to the brake hose: ^ Use a backup wrench on the hose fitting. ^ Do not bend the bracket or the pipe. ^ Tighten the fitting to 25 Nm (18 ft. lbs.). 8. Ensure that the hose does not make contact with any part of the suspension. If the hose makes contact remove the hose and correct the condition. 9. Bleed the hydraulic brake system. 10. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair Brake Proportioning/Combination Valve: Service and Repair Combination Valve Replacement Removal Procedure Important: Note the identification code on the combination valve. The new valve must have the same identification number as the old valve. 1. Remove the combination valve electrical connector. 2. Remove the front and the rear brake pipes. 3. Remove the combination valve from the vehicle. Installation Procedure Important: Verify that the replacement combination valve has the same pin punched identification code as the code on the old combination valve. 1. Install the combination valve to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the front and the rear brake pipes to the combination valve. ^ Tighten the brake pipe nuts to 25 Nm (18 ft. lbs.). 3. Connect the combination valve electrical connector. 4. Important: Verify that the combination valve metering rod is depressed during bleeding. Bleed the brake system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Replacement Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Remove the negative battery cable. 2. Important: The area around the EHCU MUST be free from loose dirt to prevent contamination of disassembled ABS components. Thoroughly wash all contaminants from around the EHCU. 3. Disconnect the chassis electrical harness connectors from the EBCM. 4. Important: Make sure that brake lines are tagged and kept in order for proper reassembly. Disconnect 5 brake lines from the BPMV. 5. Remove the bolts (4) securing the EHCU mounting bracket (3) to the frame rail (5). 6. Remove the EHCU assembly (1) from the vehicle. 7. Remove the bolts (4) securing the BPMV mounting bracket (5) to the BPMV (3). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Page 9044 8. Disconnect the 2 way ABS pump motor connector. 9. Remove the bolts (1) from the EBCM (2). 10. Notice: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. Important: Do not reuse the EBCM mounting bolts. Always install new bolts. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. 11. Clean the EBCM to BPMV mounting surfaces with a clean cloth. Installation Procedure 1. Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. Install the EBCM (2) onto BPMV (3). 2. Important: Do not reuse the old mounting bolts. Always install new bolts with the new BPMV. Install the four EBCM bolts. ^ Tighten the four bolts to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the 2 way ABS pump motor connector to the EBCM. 4. Install the BPMV (3) to BPMV bracket (5). 5. Install the BPMV to bracket retaining bolts (4). ^ Tighten the bolts to 9 Nm (7 ft. lbs.). 6. Install the EHCU assembly (1, 2) to the vehicle frame (5). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Page 9045 ^ Tighten the three EHCU bracket bolts (4) to 25 Nm (18 ft. lbs.). 7. Connect the chassis electrical harness connectors to the EBCM (1). 8. Important: The brake pipes are held in the proper place by a frame mounted plastic bracket. Make sure that the brake pipes stay in the correct place for proper reassembly. Install the 5 brake pipes to the BPMV (6). ^ Tighten the brake pipe fittings to 25 Nm (18 ft. lbs.). 9. Connect negative battery cable. 10. Bleed the brake system. Refer to ABS Automated Bleed Procedure. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications Master Cylinder Brake Lines to BPMV .................................................................................................................................................... 25 Nm (18 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) Brake Master Cylinder: Service and Repair Master Cylinder Replacement (Vacuum Boost) Master Cylinder Replacement (Vacuum Boost) Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Apply the park brake and block the wheels. 2. Disconnect the electrical connector from the brake fluid level sensor. 3. Disconnect the brake pipes from the master cylinder. 4. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Plug the open brake pipe ends. 5. Remove the master cylinder mounting nuts. 6. Remove the master cylinder from the vehicle. 7. Remove the master cylinder reservoir. Installation Procedure 1. Install the master cylinder reservoir. 2. Bench bleed the master cylinder. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 9051 3. Install the master cylinder to the vehicle. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the master cylinder mounting nuts. ^ Tighten the nuts to 33 Nm (24 ft. lbs.). 5. Remove the rubber cap or plug from the exposed brake pipe fitting ends. 6. Connect the brake pipes. ^ Tighten the fittings to 25 Nm (18 ft. lbs.). 7. Connect the electrical connector to the brake fluid level sensor. 8. Bleed the hydraulic brake system. 9. Release the park brake and unblock the wheels. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 9052 Brake Master Cylinder: Service and Repair Master Cylinder Replacement (Hydraulic Boost) Master Cylinder Replacement (Hydraulic Boost) Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Apply the park brake and block the wheels. 2. Disconnect the electrical connector from the brake fluid level sensor. 3. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Disconnect the brake pipes from the master cylinder. 4. Plug the open brake pipe ends. 5. Remove the master cylinder mounting nuts. 6. Remove the master cylinder from the vehicle. 7. Remove the master cylinder reservoir. Installation Procedure 1. Install the master cylinder reservoir. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 9053 2. Bench bleed the master cylinder. 3. Install the master cylinder to the vehicle. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the master cylinder mounting nuts. ^ Tighten the nuts to 33 Nm (24 ft. lbs.). 5. Remove the rubber cap or plug from the exposed brake pipe fitting ends. 6. Connect the brake pipes. ^ Tighten the pipe fittings to 25 Nm (18 ft. lbs.). 7. Connect the electrical connector to the brake fluid level sensor. 8. Bleed the hydraulic brake system. 9. Release the park brake and unblock the wheels. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 9054 Brake Master Cylinder: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11® (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports.As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 9055 Brake Master Cylinder: Service and Repair Master Cylinder Fluid Level Sensor Replacement Master Cylinder Fluid Level Sensor Replacement Removal Procedure 1. Disconnect the electrical connector from the fluid level sensor. 2. Using needle nose pliers, compress the locking tabs at the opposite side of the master cylinder. 3. Remove the fluid level sensor. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 9056 1. Install the fluid level sensor until the locking tabs snap into place. 2. Connect the electrical connector to the fluid level sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 9057 Brake Master Cylinder: Service and Repair Master Cylinder Replacement (Vacuum Boost) Master Cylinder Replacement (Vacuum Boost) Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Apply the park brake and block the wheels. 2. Disconnect the electrical connector from the brake fluid level sensor. 3. Disconnect the brake pipes from the master cylinder. 4. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Plug the open brake pipe ends. 5. Remove the master cylinder mounting nuts. 6. Remove the master cylinder from the vehicle. 7. Remove the master cylinder reservoir. Installation Procedure 1. Install the master cylinder reservoir. 2. Bench bleed the master cylinder. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 9058 3. Install the master cylinder to the vehicle. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the master cylinder mounting nuts. ^ Tighten the nuts to 33 Nm (24 ft. lbs.). 5. Remove the rubber cap or plug from the exposed brake pipe fitting ends. 6. Connect the brake pipes. ^ Tighten the fittings to 25 Nm (18 ft. lbs.). 7. Connect the electrical connector to the brake fluid level sensor. 8. Bleed the hydraulic brake system. 9. Release the park brake and unblock the wheels. Master Cylinder Replacement (Hydraulic Boost) Master Cylinder Replacement (Hydraulic Boost) Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Apply the park brake and block the wheels. 2. Disconnect the electrical connector from the brake fluid level sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 9059 3. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. Disconnect the brake pipes from the master cylinder. 4. Plug the open brake pipe ends. 5. Remove the master cylinder mounting nuts. 6. Remove the master cylinder from the vehicle. 7. Remove the master cylinder reservoir. Installation Procedure 1. Install the master cylinder reservoir. 2. Bench bleed the master cylinder. 3. Install the master cylinder to the vehicle. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the master cylinder mounting nuts. ^ Tighten the nuts to 33 Nm (24 ft. lbs.). 5. Remove the rubber cap or plug from the exposed brake pipe fitting ends. 6. Connect the brake pipes. ^ Tighten the pipe fittings to 25 Nm (18 ft. lbs.). 7. Connect the electrical connector to the brake fluid level sensor. 8. Bleed the hydraulic brake system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 9060 9. Release the park brake and unblock the wheels. Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11® (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports.As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Master Cylinder Fluid Level Sensor Replacement Master Cylinder Fluid Level Sensor Replacement Removal Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 9061 1. Disconnect the electrical connector from the fluid level sensor. 2. Using needle nose pliers, compress the locking tabs at the opposite side of the master cylinder. 3. Remove the fluid level sensor. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 9062 1. Install the fluid level sensor until the locking tabs snap into place. 2. Connect the electrical connector to the fluid level sensor. Master Cylinder Overhaul Master Cylinder Overhaul Disassembly Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. 1. Remove the brake master cylinder from the vehicle. 2. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 3. Clean the outside of the master cylinder reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 4. Remove the reservoir cap and diaphragm from the reservoir. 5. Inspect the reservoir cap and diaphragm for the following conditions. If any of these conditions are present, replace the affected component(s). ^ Cuts or cracks ^ Nicks or deformation 6. Remove the master cylinder reservoir from the master cylinder. 7. Using a smooth, round-ended tool, depress the primary piston (2) and remove the piston retainer. 8. Remove the primary piston assembly from the cylinder bore. 9. Plug the cylinder inlet ports and the rear outlet port. Apply low pressure, non-lubricated, filtered air into the front outlet port, in order the remove the secondary piston (1) with the primary (6) and secondary (5) seals, and the return spring. 10. Discard the primary piston assembly, the piston retainer, and the seals and seal retainer from the secondary piston. Assembly Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 9063 1. Important: Do not use abrasives to clean the brake master cylinder bore. Clean the interior and exterior of the master cylinder, the secondary piston (1), and the return spring in denatured alcohol, or equivalent. 2. Inspect the master cylinder bore, inlet and outlet ports, the secondary piston (1), and the return spring for cracks, scoring, pitting, and/or corrosion. Replace the master cylinder if any of these conditions exist. 3. Dry the master cylinder and the individual components with non-lubricated, filtered air. 4. Lubricate the master cylinder bore, the secondary piston (1), the return spring, and all of the individual overhaul components with Delco Supreme 11® (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 5. Assemble the lubricated, new primary seal (6) and retainer, and new secondary seal (5) onto the secondary piston. 6. Install the lubricated return spring and secondary piston assembly (1) into the cylinder bore. 7. Install the lubricated, new primary piston assembly (2) into the cylinder bore. 8. Using a smooth, round-ended tool, depress the primary piston (2) and install the new piston retainer. 9. Install the master cylinder reservoir to the master cylinder. 10. Install the reservoir cap and diaphragm to the reservoir. 11. Install the master cylinder to the vehicle. Master Cylinder Reservoir Replacement Master Cylinder Reservoir Replacement Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Apply the park brake and block the wheels. 2. Remove the master cylinder. 3. Drain the master cylinder reservoir. 4. Secure the master cylinder in a vise. Do not clamp the master cylinder body, secure only at the flange. 5. Remove the brake fluid level sensor by carefully depressing the retaining tabs and pushing the sensor through the reservoir. Carefully remove the reservoir retaining pins. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 9064 6. Remove the reservoir from the master cylinder by pulling the reservoir straight up and away from the cylinder. 7. Remove the seals from the master cylinder. Installation Procedure 1. Inspect the reservoir for cracks or deformation. If found, replace the reservoir. 2. Clean the reservoir with denatured alcohol, or equivalent. 3. Dry the reservoir with non-lubricated, filtered air. 4. Lubricate the new seals and the outer surface area of the reservoir-to-housing barrels with Delco Supreme 11® (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 5. Install the lubricated seals, make sure they are fully seated. 6. Install the reservoir to the master cylinder by pressing the reservoir straight down on the master cylinder until the pin holes are aligned. 7. Carefully install the reservoir retaining pins to secure the reservoir. 8. Place the brake fluid level sensor into the reservoir, press into place to secure the sensor retaining tabs. 9. Remove the master cylinder from the vice. 10. Install the master cylinder. 11. Release the park brake. 12. Bleed the hydraulic brake system. Master Cylinder Reservoir Filling Master Cylinder Reservoir Filling Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Replacement (Vacuum Boost) > Page 9065 may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Visually inspect the brake fluid level through the brake master cylinder reservoir. 2. If the brake fluid level is at or below the half-full point during routine fluid checks, the brake system should be inspected for wear and possible brake fluid leaks. 3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an inspection of the brake system did not reveal wear or brake fluid leaks, the brake fluid may be topped-off up to the maximum-fill level. 4. If brake system service was just completed, the brake fluid may be topped-off up to the maximum-fill level. 5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended under normal conditions. 6. If brake fluid is to be added to the master cylinder reservoir, clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Use only Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Backing Plate > Component Information > Specifications Parking Brake Backing Plate: Specifications Backing Plate Bolts .............................................................................................................................. ................................................ 135 Nm (100 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Recalls for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification Technical Service Bulletin # 05042B Date: 060227 Recall - Parking Brake System Modification Bulletin No.: 05042B Date: February 27, 2006 SAFETY Subject: 05042B - PARKING BRAKE SHOE AND DRUM CONTACT Models: 1999-2002 CHEVROLET 1500 SILVERADO 2001-2005 CHEVROLET 2500/3500 SILVERADO, GVWR Greater then or equal to 9200 # 1999-2002 GMC 1500 SIERRA 2001-2005 GMC 2500/3500 SIERRA, GVWR Greater then or equal to 9200 # EQUIPPED WITH A MANUAL TRANSMISSION Supercede: STEP 11.2 IN THE SERVICE PROCEDURE FOR THE 2500/3500 SERIES VEHICLES HAS BEEN REVISED. DISCARD ALL COPIES OF BULLETIN 05042A ISSUED JANUARY 2006. Condition General Motors has decided that a detect which relates to motor vehicle safety exists in certain 1999-2002 Chevrolet Silverado and GMC Sierra 1500 Series, and 2001-2005 Chevrolet Silverado and GMC Sierra 2500/3500 Series vehicles equipped with a manual transmission. Some of these vehicles may have a contact condition between the parking brake shoes and parking brake drums when the parking brake is not applied. If this were to occur, the driver may or may not hear an intermittent scraping noise from the rear of the vehicle while driving. This condition could cause parking brake lining wear. If this lining wear is undetected, the parking brake may become ineffective in immobilizing a parked vehicle on a grade. An ineffective parking brake may result in a vehicle crash. Correction 1500 Series - Dealers are to inspect the parking brake lining thickness on both rear brakes, and depending on the amount of lining remaining, install either a reduced-force parking brake retainer spring clip on both rear brakes or parking brake shoe kits, which includes the reduced-force clips. 2500-3500 Series - Dealers are to inspect the parking brake lining thickness on both rear brakes and install a new rear right-hand parking brake cable assembly. Also, depending on the amount of lining remaining, install new parking brake shoes (both rear brakes). Vehicles Involved Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Recalls for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9082 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Recalls for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9083 Involved are certain 1999-2002 Chevrolet Silverado and GMC Sierra 1500 Series, and 2001-2005 Chevrolet Silverado and GMC Sierra 2500/3500 Series vehicles equipped with a manual transmission and built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US and Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Recalls for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9084 Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada & Export Customer requests for reimbursement of previously paid repairs to correct the condition covered in this bulletin are to be submitted by August 31, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Recalls for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9085 performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuffle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Claim Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Recalls for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9086 Submit a Product Recall Claim with the information shown. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Recalls for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9087 this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure 1500 Series Vehicles ^ J 46277 Rotor Removal Tool ^ J 6125-B Slide Hammer 1. Raise and suitably support the vehicle. 2. Remove the rear tire and wheel assemblies. 3. Remove the rear caliper bolts on one side. 4. Remove the caliper from the rotor (drum-in-hat) and support. Note: Use J 46277, Rotor Removal Tool, with J 6125-B, Slide Hammer, to remove the rotor from the vehicle. Place J 46277 between the rotor surfaces in the vent section of the rotor. DO NOT place J 46277 on the back side of the rotor surface; it may damage the rotor surface. 5. Remove the rear rotor. 6. Remove the park brake shoe retaining clip (2). 7. Repeat Steps 3 through 6 for the other side. 8. Inspect the parking brake shoe lining (1) thickness in at least 6 places on each side of the vehicle. If the lining thickness is less than 1.5 mm (0.06 in) at any spot, install a new parking brake shoe on both sides. 9. Install a new park brake shoe retaining clip. If the parking brake shoe was replaced in the previous step, the new retaining clip was included in the kit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Recalls for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9088 Tighten Tighten the bolt to 3 N.m (25 lb in). 10. Grind out the ridge in the drum section of the rotor, if necessary. 11. Adjust the lining-to-drum clearance at the rear wheel to 0.6604 mm (0.026 in). 12. Install the rotor. 13. Install the caliper to the rotor. 14. Perform the following procedure before installing the caliper guide pin bolts. 14.1. Remove all traces of the original adhesive patch. 14.2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 14.3. Apply Threadlocker, GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 15. Install the caliper bolts. Tighten Tighten the caliper guide pin bolts to 42 N.m (31 lb ft). 16. Repeat Steps 9 through 13 for the other rear caliper. 17. Install the tire and wheel assemblies. Note: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel studs, nuts, or mounting surface, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in a wheel, nut, and/or stud damage. Important: Tighten the nuts evenly and alternately in order to avoid excessive run out. 18. Install the wheel nuts. Tighten Tighten the wheel nuts as shown to 190 N.m (140 lb ft). 19. Lower the vehicle. 2500/3500 Series Vehicles ^ J 46277 Rotor Removal Tool ^ J 6125-B Slide Hammer ^ J 2222-C Wheel Bearing Nut Wrench, or equivalent Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Recalls for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9089 ^ J 8092 Universal Driver Handle - 3/4 inch - 10 ^ J 44420 Differential Bearing and Hub Seal Installer 1. Hold the park brake activation pedal in the FULL upward position. 2. Pull rearward on the front park brake cable until the pedal drum (2) reaches its full reset position. 3. Insert a scribe or the shaft of a thin screwdriver (1) on an upward angle through the hole in the front of the pedal assembly, past the retracted pedal drum, and into the hole in the back of the pedal assembly (3). 4. Slowly release the cable. 5. Raise and suitably support the vehicle. 6. Remove the rear tire and wheels assemblies. 7. Remove the rear caliper bolts on one side. 8. Remove the caliper from the rotor (drum-in-hat) and support. Do not leave the caliper hanging from the hydraulic lines. Note: Use J 46277 Rotor Removal Tool with J 6125-B Slide Hammer to remove the rotor from the vehicle. Place J 46277 between the rotor surfaces in the vent section of the rotor. DO NOT place J 46277 on the back side of the rotor surface; it may damage the rotor surface. 9. For non dual rear wheels: Remove the rear rotor. For dual rear wheels: Perform Steps 12 through 16 before Step 10. 10. Repeat Steps 7 through 9 for the other side of the vehicle. 11. Inspect the parking brake shoe lining thickness in at least 6 places on each side of the vehicle. 11.1. If the lining thickness is less than 1.5 mm (0.06 in) at any spot, install new parking brake shoes on both sides of the vehicle. ^ Non dual rear wheels: Continue to Step 12. ^ Dual rear wheels: Continue to Step 17. 11.2. If the lining thickness is more that 1.5 mm (0.06 in) in all spots, new parking brake shoes are not necessary. ^ Non dual rear wheels: Perform Steps 25 and 26, and then go to Step 38. ^ Dual rear wheels: Continue to Step 25. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Recalls for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9090 12. Remove the axle shaft bolts and axle shaft. 12.1. Remove the flange bolts. 12.2. Lightly tap the axle shaft with a soft-faced hammer in order to loosen the shaft. 12.3. Grip the rib on the axle shaft flange with a pair of locking pliers. Twist the axle shaft flange in order to start the axle shaft removal 12.4. Remove the axle shaft from the tube. 12.5. Remove the gasket 12.6. Clean the axle shaft flange and the outside face of the hub assembly. 13. Remove the axle nut retaining ring. 14. Remove the key. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Recalls for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9091 15. Remove the adjusting nut using the J 2222-C. 16. Remove the hub from the axle housing. 17. Remove the park brake shoe return spring (6). 18. Remove the park brake shoe anchor springs and pins (3). 19. Separate the tips of the shoes from the park brake actuator and remove the park brake shoes (2) and adjuster assembly (5) from the vehicle. 20. Clean the debris and the dust from the park brake components using a clean shop cloth. 21. Install the adjuster assembly to the park brake shoes. 22. Separate the tips of the shoes and install the park brake shoes to the park brake actuator. 23. Install the park brake shoe anchor springs and pins. 24. Install the park brake shoe return spring (6). 25. Grind out the ridge in drum section of rotor if necessary. 26. Adjust the lining-to-drum clearance at the rear wheel to 0.6604 mm (.026 in). 27. Replace the hub seal using the J 44420, differential bearing and hub seal installer (2) and the J 8092, universal driver handle (1). 28. Install the hub to the axle housing. 29. Install and tighten the wheel bearing adjusting nut using the J 2222-C. Rotate the hub in the opposite direction to the way the adjuster nut is turning. Ensure that the inner bearing and the seal seats against the spindle shoulder. Tighten Tighten the adjusting nut to 70 N.m (52 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Recalls for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9092 30. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 31. Turn the adjusting nut clockwise until the nut contacts the bearing cone. The torque on the nut must be zero to finger tight. 32. Insert the adjusting nut lock key into the keyway using one of the following procedures. 32.1. If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. Important: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. 32.2. If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. 33. Install the retaining ring. 34. Install the gasket and the axle shaft into the axle tube. 35. Ensure that the shaft splines mesh into the differential side gear. 36. Align the holes in the axle flange and the gasket with the holes in the hub. Note: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 37. Install the axle flange bolts. Tighten ^ For the 10.5 inch axle, tighten the rear axle flange bolts to 156 N.m (115 lb ft). ^ For the 11.5 inch axle, tighten the rear axle flange bolts to 200 N.m (148 lb ft). 38. Install the rotor. 39. Perform the following procedure before installing the brake caliper mounting bracket bolts: 39.1 Remove all traces of the original adhesive patch. 39.2 Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 39.3 Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 40. Install the brake caliper assembly and bolts. Tighten the brake caliper mounting bracket bolts to ^ RPO JC5/JH5 to 200 N.m (148 lb ft) ^ RPO JH6 to 165 N.m (122 lb ft) ^ RPO JH7 to 300 N.m (221 lb ft) 41. Repeat this procedure for other side starting with Step 11. 42. Disconnect the cable for the right rear from the equalizer. 43. Remove the bolt from the rear axle clip. 44. Remove the cable from the differential clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Recalls for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9093 45. Perform the following procedure to remove the cable (2) from the backing plate (4): 45.1 Compress the spring (3) by pushing towards the lever (1). 45.2 Depress the locking tabs. 45.3 Pull the cable housing out of the backing plate (4). 45.4 Remove the cable (2) through the slot in the backing plate. 46. Remove the park brake cable (2) from the lever (1). 47. Remove the cable from the vehicle. 48. Install the new cable to the vehicle. 49. Install the park brake cable (2) to the lever (1). 50. Perform the following procedure to install the cable (2) to the backing plate (4): 50.1 Compress the spring (3) by pushing towards the lever (1). 50.2 Route the cable (2) through the slot in the backing plate. 50.3 Push the cable housing into the backing plate (4) until the locking tabs snap into place. 51. Bolt the cable to the differential clips. Tighten Tighten the bolt to 25 N.m (18 lb ft). Important: After installing the cable to the rear axle holding clip, verify that the clip is securely retaining the cable. If not, crimp the clip by hand, taking care not to pinch or kink the cable. 52. Install the cable to the differential clip. 53. Connect the cable at the equalizer. 54. Install the wheels and tires. 55. Hold the park brake pedal in the FULL upward position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Recalls for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9094 56. Pull rearward on the front park brake cable until the tension is released from the scribe or nail (1) installed through the holes in the pedal assembly. 57. Remove the scribe or screwdriver (1). 58. Slowly release the park brake cable until it returns to its original position. 59. Release the park brake pedal. Note: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel studs, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage. 60. Install the tire and wheel. 61. Install the wheel nuts. Tighten Tighten the wheel nuts as shown to 190 N.m (140 lb ft). 62. Install the wheel center cap. 63. Lower the vehicle. 64. Apply and release the park brake pedal to ensure that there is no binding or sticking. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Recalls for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9095 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Recalls for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9096 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Recalls for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9097 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification Technical Service Bulletin # 05042B Date: 060227 Recall - Parking Brake System Modification Bulletin No.: 05042B Date: February 27, 2006 SAFETY Subject: 05042B - PARKING BRAKE SHOE AND DRUM CONTACT Models: 1999-2002 CHEVROLET 1500 SILVERADO 2001-2005 CHEVROLET 2500/3500 SILVERADO, GVWR Greater then or equal to 9200 # 1999-2002 GMC 1500 SIERRA 2001-2005 GMC 2500/3500 SIERRA, GVWR Greater then or equal to 9200 # EQUIPPED WITH A MANUAL TRANSMISSION Supercede: STEP 11.2 IN THE SERVICE PROCEDURE FOR THE 2500/3500 SERIES VEHICLES HAS BEEN REVISED. DISCARD ALL COPIES OF BULLETIN 05042A ISSUED JANUARY 2006. Condition General Motors has decided that a detect which relates to motor vehicle safety exists in certain 1999-2002 Chevrolet Silverado and GMC Sierra 1500 Series, and 2001-2005 Chevrolet Silverado and GMC Sierra 2500/3500 Series vehicles equipped with a manual transmission. Some of these vehicles may have a contact condition between the parking brake shoes and parking brake drums when the parking brake is not applied. If this were to occur, the driver may or may not hear an intermittent scraping noise from the rear of the vehicle while driving. This condition could cause parking brake lining wear. If this lining wear is undetected, the parking brake may become ineffective in immobilizing a parked vehicle on a grade. An ineffective parking brake may result in a vehicle crash. Correction 1500 Series - Dealers are to inspect the parking brake lining thickness on both rear brakes, and depending on the amount of lining remaining, install either a reduced-force parking brake retainer spring clip on both rear brakes or parking brake shoe kits, which includes the reduced-force clips. 2500-3500 Series - Dealers are to inspect the parking brake lining thickness on both rear brakes and install a new rear right-hand parking brake cable assembly. Also, depending on the amount of lining remaining, install new parking brake shoes (both rear brakes). Vehicles Involved Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9103 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9104 Involved are certain 1999-2002 Chevrolet Silverado and GMC Sierra 1500 Series, and 2001-2005 Chevrolet Silverado and GMC Sierra 2500/3500 Series vehicles equipped with a manual transmission and built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US and Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9105 Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada & Export Customer requests for reimbursement of previously paid repairs to correct the condition covered in this bulletin are to be submitted by August 31, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9106 performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuffle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Claim Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9107 Submit a Product Recall Claim with the information shown. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9108 this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure 1500 Series Vehicles ^ J 46277 Rotor Removal Tool ^ J 6125-B Slide Hammer 1. Raise and suitably support the vehicle. 2. Remove the rear tire and wheel assemblies. 3. Remove the rear caliper bolts on one side. 4. Remove the caliper from the rotor (drum-in-hat) and support. Note: Use J 46277, Rotor Removal Tool, with J 6125-B, Slide Hammer, to remove the rotor from the vehicle. Place J 46277 between the rotor surfaces in the vent section of the rotor. DO NOT place J 46277 on the back side of the rotor surface; it may damage the rotor surface. 5. Remove the rear rotor. 6. Remove the park brake shoe retaining clip (2). 7. Repeat Steps 3 through 6 for the other side. 8. Inspect the parking brake shoe lining (1) thickness in at least 6 places on each side of the vehicle. If the lining thickness is less than 1.5 mm (0.06 in) at any spot, install a new parking brake shoe on both sides. 9. Install a new park brake shoe retaining clip. If the parking brake shoe was replaced in the previous step, the new retaining clip was included in the kit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9109 Tighten Tighten the bolt to 3 N.m (25 lb in). 10. Grind out the ridge in the drum section of the rotor, if necessary. 11. Adjust the lining-to-drum clearance at the rear wheel to 0.6604 mm (0.026 in). 12. Install the rotor. 13. Install the caliper to the rotor. 14. Perform the following procedure before installing the caliper guide pin bolts. 14.1. Remove all traces of the original adhesive patch. 14.2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 14.3. Apply Threadlocker, GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 15. Install the caliper bolts. Tighten Tighten the caliper guide pin bolts to 42 N.m (31 lb ft). 16. Repeat Steps 9 through 13 for the other rear caliper. 17. Install the tire and wheel assemblies. Note: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel studs, nuts, or mounting surface, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in a wheel, nut, and/or stud damage. Important: Tighten the nuts evenly and alternately in order to avoid excessive run out. 18. Install the wheel nuts. Tighten Tighten the wheel nuts as shown to 190 N.m (140 lb ft). 19. Lower the vehicle. 2500/3500 Series Vehicles ^ J 46277 Rotor Removal Tool ^ J 6125-B Slide Hammer ^ J 2222-C Wheel Bearing Nut Wrench, or equivalent Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9110 ^ J 8092 Universal Driver Handle - 3/4 inch - 10 ^ J 44420 Differential Bearing and Hub Seal Installer 1. Hold the park brake activation pedal in the FULL upward position. 2. Pull rearward on the front park brake cable until the pedal drum (2) reaches its full reset position. 3. Insert a scribe or the shaft of a thin screwdriver (1) on an upward angle through the hole in the front of the pedal assembly, past the retracted pedal drum, and into the hole in the back of the pedal assembly (3). 4. Slowly release the cable. 5. Raise and suitably support the vehicle. 6. Remove the rear tire and wheels assemblies. 7. Remove the rear caliper bolts on one side. 8. Remove the caliper from the rotor (drum-in-hat) and support. Do not leave the caliper hanging from the hydraulic lines. Note: Use J 46277 Rotor Removal Tool with J 6125-B Slide Hammer to remove the rotor from the vehicle. Place J 46277 between the rotor surfaces in the vent section of the rotor. DO NOT place J 46277 on the back side of the rotor surface; it may damage the rotor surface. 9. For non dual rear wheels: Remove the rear rotor. For dual rear wheels: Perform Steps 12 through 16 before Step 10. 10. Repeat Steps 7 through 9 for the other side of the vehicle. 11. Inspect the parking brake shoe lining thickness in at least 6 places on each side of the vehicle. 11.1. If the lining thickness is less than 1.5 mm (0.06 in) at any spot, install new parking brake shoes on both sides of the vehicle. ^ Non dual rear wheels: Continue to Step 12. ^ Dual rear wheels: Continue to Step 17. 11.2. If the lining thickness is more that 1.5 mm (0.06 in) in all spots, new parking brake shoes are not necessary. ^ Non dual rear wheels: Perform Steps 25 and 26, and then go to Step 38. ^ Dual rear wheels: Continue to Step 25. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9111 12. Remove the axle shaft bolts and axle shaft. 12.1. Remove the flange bolts. 12.2. Lightly tap the axle shaft with a soft-faced hammer in order to loosen the shaft. 12.3. Grip the rib on the axle shaft flange with a pair of locking pliers. Twist the axle shaft flange in order to start the axle shaft removal 12.4. Remove the axle shaft from the tube. 12.5. Remove the gasket 12.6. Clean the axle shaft flange and the outside face of the hub assembly. 13. Remove the axle nut retaining ring. 14. Remove the key. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9112 15. Remove the adjusting nut using the J 2222-C. 16. Remove the hub from the axle housing. 17. Remove the park brake shoe return spring (6). 18. Remove the park brake shoe anchor springs and pins (3). 19. Separate the tips of the shoes from the park brake actuator and remove the park brake shoes (2) and adjuster assembly (5) from the vehicle. 20. Clean the debris and the dust from the park brake components using a clean shop cloth. 21. Install the adjuster assembly to the park brake shoes. 22. Separate the tips of the shoes and install the park brake shoes to the park brake actuator. 23. Install the park brake shoe anchor springs and pins. 24. Install the park brake shoe return spring (6). 25. Grind out the ridge in drum section of rotor if necessary. 26. Adjust the lining-to-drum clearance at the rear wheel to 0.6604 mm (.026 in). 27. Replace the hub seal using the J 44420, differential bearing and hub seal installer (2) and the J 8092, universal driver handle (1). 28. Install the hub to the axle housing. 29. Install and tighten the wheel bearing adjusting nut using the J 2222-C. Rotate the hub in the opposite direction to the way the adjuster nut is turning. Ensure that the inner bearing and the seal seats against the spindle shoulder. Tighten Tighten the adjusting nut to 70 N.m (52 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9113 30. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 31. Turn the adjusting nut clockwise until the nut contacts the bearing cone. The torque on the nut must be zero to finger tight. 32. Insert the adjusting nut lock key into the keyway using one of the following procedures. 32.1. If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. Important: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. 32.2. If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. 33. Install the retaining ring. 34. Install the gasket and the axle shaft into the axle tube. 35. Ensure that the shaft splines mesh into the differential side gear. 36. Align the holes in the axle flange and the gasket with the holes in the hub. Note: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 37. Install the axle flange bolts. Tighten ^ For the 10.5 inch axle, tighten the rear axle flange bolts to 156 N.m (115 lb ft). ^ For the 11.5 inch axle, tighten the rear axle flange bolts to 200 N.m (148 lb ft). 38. Install the rotor. 39. Perform the following procedure before installing the brake caliper mounting bracket bolts: 39.1 Remove all traces of the original adhesive patch. 39.2 Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 39.3 Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 40. Install the brake caliper assembly and bolts. Tighten the brake caliper mounting bracket bolts to ^ RPO JC5/JH5 to 200 N.m (148 lb ft) ^ RPO JH6 to 165 N.m (122 lb ft) ^ RPO JH7 to 300 N.m (221 lb ft) 41. Repeat this procedure for other side starting with Step 11. 42. Disconnect the cable for the right rear from the equalizer. 43. Remove the bolt from the rear axle clip. 44. Remove the cable from the differential clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9114 45. Perform the following procedure to remove the cable (2) from the backing plate (4): 45.1 Compress the spring (3) by pushing towards the lever (1). 45.2 Depress the locking tabs. 45.3 Pull the cable housing out of the backing plate (4). 45.4 Remove the cable (2) through the slot in the backing plate. 46. Remove the park brake cable (2) from the lever (1). 47. Remove the cable from the vehicle. 48. Install the new cable to the vehicle. 49. Install the park brake cable (2) to the lever (1). 50. Perform the following procedure to install the cable (2) to the backing plate (4): 50.1 Compress the spring (3) by pushing towards the lever (1). 50.2 Route the cable (2) through the slot in the backing plate. 50.3 Push the cable housing into the backing plate (4) until the locking tabs snap into place. 51. Bolt the cable to the differential clips. Tighten Tighten the bolt to 25 N.m (18 lb ft). Important: After installing the cable to the rear axle holding clip, verify that the clip is securely retaining the cable. If not, crimp the clip by hand, taking care not to pinch or kink the cable. 52. Install the cable to the differential clip. 53. Connect the cable at the equalizer. 54. Install the wheels and tires. 55. Hold the park brake pedal in the FULL upward position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9115 56. Pull rearward on the front park brake cable until the tension is released from the scribe or nail (1) installed through the holes in the pedal assembly. 57. Remove the scribe or screwdriver (1). 58. Slowly release the park brake cable until it returns to its original position. 59. Release the park brake pedal. Note: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel studs, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage. 60. Install the tire and wheel. 61. Install the wheel nuts. Tighten Tighten the wheel nuts as shown to 190 N.m (140 lb ft). 62. Install the wheel center cap. 63. Lower the vehicle. 64. Apply and release the park brake pedal to ensure that there is no binding or sticking. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9116 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9117 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9118 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Page 9119 Parking Brake Cable: Specifications Park Brake Cable Bracket to Knuckle Bolt (NYS) ................................................................................................................................... 61 Nm (45 ft. lbs.) Park Brake Cable Guide to Frame Bolt ............................................................................................................................................... 12 Nm (106 inch lbs.) Park Brake Cable to Rear Axle Clip Bolt ................................................................................................................................................. 25 Nm (18 ft. lbs.) Park Brake Cable to Shock Absorber Bracket Bolt .................................................................................................................................. 25 Nm (18 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Adjustments > Disabling the Park Brake Cable Automatic Adjuster Parking Brake Cable: Adjustments Disabling the Park Brake Cable Automatic Adjuster Disabling the Park Brake Cable Automatic Adjuster Before any components of the parking brake system are serviced, the following procedure must be followed. Two technicians are required to perform this procedure: one inside the vehicle and one outside the vehicle. 1. Raise and support the vehicle. Refer Vehicle Lifting 2. Hold the pedal in the FULL upward position. 3. Pull rearward on the front park brake cable until the pedal drum (2) reaches its full reset position. 4. Insert a scribe or the shaft of a thin screwdriver (1) on an upward angle through the hole in the front of the pedal assembly, past the retracted pedal drum, and into the hole in the back of the pedal assembly (3). 5. Slowly release the cable. 6. Remove the component that requires service. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Adjustments > Disabling the Park Brake Cable Automatic Adjuster > Page 9122 Parking Brake Cable: Adjustments Enabling the Park Brake Cable Automatic Adjuster Enabling the Park Brake Cable Automatic Adjuster If the park brake automatic adjuster has been disabled, the following two person procedure must be performed. 1. Hold the park brake pedal in the FULL upward position. 2. Pull rearward on the front park brake cable until the tension is released from the scribe or nail (1) installed through the holes in the pedal assembly. 3. Remove the scribe or screwdriver (1). 4. Slowly release the park brake cable until it returns to its original position. 5. Release the park brake pedal. 6. Lower the vehicle. 7. Apply and release the park brake pedal to ensure that there is no binding or sticking. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement Parking Brake Cable: Service and Repair Park Brake Cable Guide Replacement Park Brake Cable Guide Replacement Removal Procedure 1. Release the parking brake. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. Remove the park brake cable guide bolt from the frame. 4. Remove the park brake cable guide. 5. Remove the park brake guide from the park brake cable. Installation Procedure 1. Install the park brake cable guide to the park brake cable. 2. Install the park brake cable guide. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake cable guide bolt to the frame. ^ Tighten the bolt to 12 Nm (106 inch lbs.). 4. Remove the safety stands. 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9125 Parking Brake Cable: Service and Repair Park Brake Cable Replacement - Front Park Brake Cable Replacement - Front Removal Procedure 1. Release the park brake. 2. Remove the park brake pedal. Refer to Park Brake Pedal Assembly Replacement. 3. Roll the carpet back to access cable grommet. 4. Raise and support the vehicle. Refer Vehicle Lifting 5. Disengage the grommet and the cable from the floor pan. 6. Disconnect the front cable from the intermediate cable. 7. Remove the cable from the body mount by depressing the retaining tabs. 8. Remove the cable. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9126 1. Install the cable. 2. Snap the retainer tabs into the body mount. 3. Connect the front cable to the intermediate cable. 4. Route the cable in through the floor pan and engage the grommet. 5. Remove the safety stands. 6. Lower the vehicle. 7. Roll the carpet into place. 8. Install the park brake pedal. Refer to Park Brake Pedal Assembly Replacement. 9. Adjust the park brake system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9127 Parking Brake Cable: Service and Repair Park Brake Cable Replacement - Left Rear (W/O NYS) Park Brake Cable Replacement - Left Rear (w/o NYS) Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. For all 15 series vehicles, relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer and removing the left park brake cable from the equalizer bar. 4. For 25/35 series vehicles, disable the park brake cable automatic adjuster. Refer to Disabling the Park Brake Cable Automatic Adjuster. 5. For 25/35 series vehicles, disconnect the cable at the equalizer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9128 6. Remove the cable from the mounting bracket by depressing the locking tabs. 7. Remove the cable at the shock absorber bracket by removing the bolt. 8. Perform the following procedure to remove the cable (2) from the backing plate (4): 1. Compress the spring (3) by pushing towards the lever (1). 2. Depress the locking tabs. 3. Pull the cable housing out of the backing plate (4). 4. Remove the cable (2) through the slot in the backing plate. 9. Remove the park brake cable (2) from the lever (1). 10. Remove the cable from the vehicle. Installation Procedure 1. Install the cable to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9129 2. Install the park brake cable (2) to the lever (1). 3. Perform the following procedure to install the cable (2) to the backing plate (4): 1. Compress the spring (3) by pushing towards the lever (1). 2. Route the cable (2) through the slot in the backing plate. 3. Push the cable housing into the backing plate (4) until the locking tabs snap into place. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the cable at the shock absorber bracket and install the bolt. ^ Tighten the bolt to 25 Nm (18 ft. lbs.). 5. Install the cable to the mounting bracket until the locking tabs snap into place. 6. For 25/35 series vehicles, connect the cable at the equalizer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9130 7. For 25/35 series vehicles, enable the park brake cable automatic adjuster. Refer to Enabling the Park Brake Cable Automatic Adjuster. 8. For all 15 series vehicles, pull down on the park brake cable in front of the equalizer and install the left park brake cable to the equalizer bar. 9. Remove the safety stands. 10. Remove the safety stands and lower the vehicle. 11. Adjust the park brake cable. (W/NYS) Park Brake Cable Replacement - Left Rear (w/NYS) Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer Vehicle Lifting Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9131 3. Relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer and removing the left park brake cable from the equalizer bar. 4. Remove the cable from the mounting bracket by depressing the locking tabs. 5. Remove the cable at the lower shock absorber mount by removing the bolt. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9132 6. Remove the rear cable mounting bracket bolt. 7. Remove the cable from the lever. 8. Remove the cable (2) from the rear brake cable mounting bracket (3) by depressing the locking tabs (1) on the brake cable. 9. Remove the cable from the guides and the body mounts. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9133 1. Install the new brake cable (2) into the rear brake cable mounting bracket (3) by pushing the cable into place until the locking tabs (1) snap into place. 2. Install the park brake cable to the lever. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear park brake cable bracket bolt. ^ Tighten the rear park brake cable bracket bolt to 61 Nm (45 ft. lbs.). 4. Install the park brake cable and the bolt to the lower shock absorber mount. ^ Tighten the park brake cable bolt to 25 Nm (18 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9134 5. Install the park brake cable taking care to correctly route the cable though the guides and the body mounts. 6. Pull down on the park brake cable in front of the equalizer and install the left park brake cable to the equalizer bar. 7. Remove the safety stands. 8. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9135 Parking Brake Cable: Service and Repair Park Brake Cable Replacement - Right Rear (W/O NYS) Park Brake Cable Replacement - Right Rear (w/o NYS) Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. For all 15 series vehicles, relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer and removing the right park brake cable from the equalizer bar. 4. For 25/35 series vehicles, disable the park brake cable automatic adjuster. Refer to Disabling the Park Brake Cable Automatic Adjuster. 5. For 25/35 series vehicles, disconnect the cable at the equalizer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9136 6. Remove the bolt from the rear axle clip. 7. Remove the cable from the differential clip. 8. Remove the cable from the mounting bracket by depressing the locking tabs. 9. Perform the following procedure to remove the cable (2) from the backing plate (4): 1. Compress the spring (3) by pushing towards the lever (1). 2. Depress the locking tabs. 3. Pull the cable housing out of the backing plate (4). 4. Remove the cable (2) through the slot in the backing plate. 10. Remove the park brake cable (2) from the lever (1). 11. Remove the cable from the vehicle. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9137 1. Install the cable to the vehicle. 2. Install the park brake cable (2) to the lever (1). 3. Perform the following procedure to install the cable (2) to the backing plate (4): 1. Compress the spring (3) by pushing towards the lever (1). 2. Route the cable (2) through the slot in the backing plate. 3. Push the cable housing into the backing plate (4) until the locking tabs snap into place. 4. Install the cable to the mounting bracket until the locking tabs snap into place. 5. Notice: Refer to Fastener Notice in Service Precautions. Bolt the cable to the differential (clips). ^ Tighten the bolt to 25 Nm (18 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9138 6. Important: After installing the cable to the rear axle holding clip, verify that clip is securely retaining the cable. If not, crimp the clip by hand taking care not to pinch or kink the cable. Install the cable to the differential clip. 7. For 25/35 series vehicles, connect the cable at the equalizer. 8. For 25/35 series vehicles, enable the park brake cable automatic adjuster. Refer to Enabling the Park Brake Cable Automatic Adjuster. 9. For all 15 series vehicles, pull down on the park brake cable in front of the equalizer and install the left park brake cable to the equalizer bar. 10. Remove the safety stands. 11. Remove the safety stands and lower the vehicle. 12. Adjust the park brake cable. (W/NYS) Park Brake Cable Replacement - Right Rear (w/NYS) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9139 Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. Relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer and removing the right park brake cable from the equalizer bar. 4. Remove the cable from the mounting bracket by depressing the locking tabs. 5. Remove the park brake cable from the differential clip.Remove the bolt retaining the park brake cable from the rear axle clip. 6. Remove the rear brake cable mounting bracket bolt. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9140 7. Remove the brake cable from the lever. 8. Remove the cable (2) from the rear brake cable mounting bracket (3) by depressing the locking tabs (1) on the brake cable. 9. Remove the brake cable from the guides and the body mounts. Installation Procedure 1. Install the new brake cable (2) into the rear brake cable mounting bracket (3) by pushing the cable into place until the locking tabs (1) snap into place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9141 2. Install the park brake cable to the lever. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear park brake cable bracket bolt. ^ Tighten the rear park brake cable bracket bolt to 61 Nm (45 ft. lbs.). 4. Install the park brake cable to the differential clip. 5. Install the park brake cable bolt to the rear axle clip. ^ Tighten the park brake cable bolt to 25 Nm (18 ft. lbs.). 6. Install the park brake cable taking care to correctly route the cable though the guides and the body mounts. 7. Install the park brake cable into the mounting bracket until the locking tabs snap into place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9142 8. Pull down on the park brake cable in front of the equalizer and install the left park brake cable to the equalizer bar. 9. Remove the safety stands. 10. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9143 Parking Brake Cable: Service and Repair Park Brake Cable Guide Replacement Park Brake Cable Guide Replacement Removal Procedure 1. Release the parking brake. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. Remove the park brake cable guide bolt from the frame. 4. Remove the park brake cable guide. 5. Remove the park brake guide from the park brake cable. Installation Procedure 1. Install the park brake cable guide to the park brake cable. 2. Install the park brake cable guide. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake cable guide bolt to the frame. ^ Tighten the bolt to 12 Nm (106 inch lbs.). 4. Remove the safety stands. 5. Lower the vehicle. Park Brake Cable Replacement - Front Park Brake Cable Replacement - Front Removal Procedure 1. Release the park brake. 2. Remove the park brake pedal. Refer to Park Brake Pedal Assembly Replacement. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9144 3. Roll the carpet back to access cable grommet. 4. Raise and support the vehicle. Refer Vehicle Lifting 5. Disengage the grommet and the cable from the floor pan. 6. Disconnect the front cable from the intermediate cable. 7. Remove the cable from the body mount by depressing the retaining tabs. 8. Remove the cable. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9145 1. Install the cable. 2. Snap the retainer tabs into the body mount. 3. Connect the front cable to the intermediate cable. 4. Route the cable in through the floor pan and engage the grommet. 5. Remove the safety stands. 6. Lower the vehicle. 7. Roll the carpet into place. 8. Install the park brake pedal. Refer to Park Brake Pedal Assembly Replacement. 9. Adjust the park brake system. (W/O NYS) Park Brake Cable Replacement - Left Rear (w/o NYS) Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer Vehicle Lifting Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9146 3. For all 15 series vehicles, relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer and removing the left park brake cable from the equalizer bar. 4. For 25/35 series vehicles, disable the park brake cable automatic adjuster. Refer to Disabling the Park Brake Cable Automatic Adjuster. 5. For 25/35 series vehicles, disconnect the cable at the equalizer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9147 6. Remove the cable from the mounting bracket by depressing the locking tabs. 7. Remove the cable at the shock absorber bracket by removing the bolt. 8. Perform the following procedure to remove the cable (2) from the backing plate (4): 1. Compress the spring (3) by pushing towards the lever (1). 2. Depress the locking tabs. 3. Pull the cable housing out of the backing plate (4). 4. Remove the cable (2) through the slot in the backing plate. 9. Remove the park brake cable (2) from the lever (1). 10. Remove the cable from the vehicle. Installation Procedure 1. Install the cable to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9148 2. Install the park brake cable (2) to the lever (1). 3. Perform the following procedure to install the cable (2) to the backing plate (4): 1. Compress the spring (3) by pushing towards the lever (1). 2. Route the cable (2) through the slot in the backing plate. 3. Push the cable housing into the backing plate (4) until the locking tabs snap into place. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the cable at the shock absorber bracket and install the bolt. ^ Tighten the bolt to 25 Nm (18 ft. lbs.). 5. Install the cable to the mounting bracket until the locking tabs snap into place. 6. For 25/35 series vehicles, connect the cable at the equalizer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9149 7. For 25/35 series vehicles, enable the park brake cable automatic adjuster. Refer to Enabling the Park Brake Cable Automatic Adjuster. 8. For all 15 series vehicles, pull down on the park brake cable in front of the equalizer and install the left park brake cable to the equalizer bar. 9. Remove the safety stands. 10. Remove the safety stands and lower the vehicle. 11. Adjust the park brake cable. (W/NYS) Park Brake Cable Replacement - Left Rear (w/NYS) Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer Vehicle Lifting Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9150 3. Relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer and removing the left park brake cable from the equalizer bar. 4. Remove the cable from the mounting bracket by depressing the locking tabs. 5. Remove the cable at the lower shock absorber mount by removing the bolt. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9151 6. Remove the rear cable mounting bracket bolt. 7. Remove the cable from the lever. 8. Remove the cable (2) from the rear brake cable mounting bracket (3) by depressing the locking tabs (1) on the brake cable. 9. Remove the cable from the guides and the body mounts. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9152 1. Install the new brake cable (2) into the rear brake cable mounting bracket (3) by pushing the cable into place until the locking tabs (1) snap into place. 2. Install the park brake cable to the lever. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear park brake cable bracket bolt. ^ Tighten the rear park brake cable bracket bolt to 61 Nm (45 ft. lbs.). 4. Install the park brake cable and the bolt to the lower shock absorber mount. ^ Tighten the park brake cable bolt to 25 Nm (18 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9153 5. Install the park brake cable taking care to correctly route the cable though the guides and the body mounts. 6. Pull down on the park brake cable in front of the equalizer and install the left park brake cable to the equalizer bar. 7. Remove the safety stands. 8. Lower the vehicle. (W/O NYS) Park Brake Cable Replacement - Right Rear (w/o NYS) Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer Vehicle Lifting Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9154 3. For all 15 series vehicles, relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer and removing the right park brake cable from the equalizer bar. 4. For 25/35 series vehicles, disable the park brake cable automatic adjuster. Refer to Disabling the Park Brake Cable Automatic Adjuster. 5. For 25/35 series vehicles, disconnect the cable at the equalizer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9155 6. Remove the bolt from the rear axle clip. 7. Remove the cable from the differential clip. 8. Remove the cable from the mounting bracket by depressing the locking tabs. 9. Perform the following procedure to remove the cable (2) from the backing plate (4): 1. Compress the spring (3) by pushing towards the lever (1). 2. Depress the locking tabs. 3. Pull the cable housing out of the backing plate (4). 4. Remove the cable (2) through the slot in the backing plate. 10. Remove the park brake cable (2) from the lever (1). 11. Remove the cable from the vehicle. Installation Procedure 1. Install the cable to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9156 2. Install the park brake cable (2) to the lever (1). 3. Perform the following procedure to install the cable (2) to the backing plate (4): 1. Compress the spring (3) by pushing towards the lever (1). 2. Route the cable (2) through the slot in the backing plate. 3. Push the cable housing into the backing plate (4) until the locking tabs snap into place. 4. Install the cable to the mounting bracket until the locking tabs snap into place. 5. Notice: Refer to Fastener Notice in Service Precautions. Bolt the cable to the differential (clips). ^ Tighten the bolt to 25 Nm (18 ft. lbs.). 6. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9157 After installing the cable to the rear axle holding clip, verify that clip is securely retaining the cable. If not, crimp the clip by hand taking care not to pinch or kink the cable. Install the cable to the differential clip. 7. For 25/35 series vehicles, connect the cable at the equalizer. 8. For 25/35 series vehicles, enable the park brake cable automatic adjuster. Refer to Enabling the Park Brake Cable Automatic Adjuster. 9. For all 15 series vehicles, pull down on the park brake cable in front of the equalizer and install the left park brake cable to the equalizer bar. 10. Remove the safety stands. 11. Remove the safety stands and lower the vehicle. 12. Adjust the park brake cable. (W/NYS) Park Brake Cable Replacement - Right Rear (w/NYS) Removal Procedure 1. Release the park brake. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9158 2. Raise and support the vehicle. Refer Vehicle Lifting 3. Relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer and removing the right park brake cable from the equalizer bar. 4. Remove the cable from the mounting bracket by depressing the locking tabs. 5. Remove the park brake cable from the differential clip.Remove the bolt retaining the park brake cable from the rear axle clip. 6. Remove the rear brake cable mounting bracket bolt. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9159 7. Remove the brake cable from the lever. 8. Remove the cable (2) from the rear brake cable mounting bracket (3) by depressing the locking tabs (1) on the brake cable. 9. Remove the brake cable from the guides and the body mounts. Installation Procedure 1. Install the new brake cable (2) into the rear brake cable mounting bracket (3) by pushing the cable into place until the locking tabs (1) snap into place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9160 2. Install the park brake cable to the lever. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear park brake cable bracket bolt. ^ Tighten the rear park brake cable bracket bolt to 61 Nm (45 ft. lbs.). 4. Install the park brake cable to the differential clip. 5. Install the park brake cable bolt to the rear axle clip. ^ Tighten the park brake cable bolt to 25 Nm (18 ft. lbs.). 6. Install the park brake cable taking care to correctly route the cable though the guides and the body mounts. 7. Install the park brake cable into the mounting bracket until the locking tabs snap into place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9161 8. Pull down on the park brake cable in front of the equalizer and install the left park brake cable to the equalizer bar. 9. Remove the safety stands. 10. Lower the vehicle. Park Brake Cable Replacement - Intermediate Park Brake Cable Replacement - Intermediate Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. For all 15 series vehicles, relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer then removing the cables from the equalizer bar. 4. For 25/35 series vehicles, disable the park brake cable automatic adjuster. Refer to Disabling the Park Brake Cable Automatic Adjuster. 5. For 25/35 series vehicles, disconnect the intermediate cable from the rear park brake cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9162 6. Disconnect the intermediate cable from the front cable. 7. Remove the intermediate cable from the vehicle. Installation Procedure 1. Install the intermediate cable to the vehicle. 2. Connect the intermediate cable to the front cable. 3. For 25/35 series vehicles, connect the intermediate cable to the rear park brake cable. 4. For 15 series vehicles, install the rear park brake cables to the equalizer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9163 5. Notice: Refer to Fastener Notice in Service Precautions. For 15 series vehicles, install the equalizer and the nut to the threaded end of the intermediate cable. ^ Tighten the nut to 3.5 Nm (31 inch lbs.). 6. For 25/35 series vehicles, enable the park brake cable automatic adjuster. Refer to Enabling the Park Brake Cable Automatic Adjuster. 7. Remove the safety stands and lower the vehicle. 8. Adjust the park brake system. Park Brake Cable Mounting Bracket Replacement Park Brake Cable Mounting Bracket Replacement Removal Procedure 1. Release the parking brake. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. Release the tension on the cables by loosening the nut at the equalizer. 4. Disconnect the rear cables from the equalizer. 5. Remove the rear cables from the mounting bracket by depressing the retaining tabs and pulling rearward. 6. Remove the cable support bracket nuts. 7. Remove the cable support bracket. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9164 1. Install the cable support bracket. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the cable support bracket nuts. ^ Tighten the support bracket nuts to 85 Nm (64 ft. lbs.). 3. Install the rear cables to the mounting bracket by inserting the cable till all the retaining tabs snap into place. 4. Connect the rear cables to the equalizer. 5. Tighten the nut to the intermediate cable at the equalizer. ^ Tighten the nut to 3.5 Nm (31 inch lbs.). 6. Remove the safety stands. 7. Lower the vehicle. Park Brake Cable Equalizer Replacement Park Brake Cable Equalizer Replacement Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. For the 15 series vehicles, remove the nut from the threaded end of the intermediate cable. 4. Disconnect the equalizer from the rear park brake cables. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9165 5. For 25/35 series vehicles, disable the park brake cable automatic adjuster. Refer to Disabling the Park Brake Cable Automatic Adjuster. 6. For 25/35 series vehicles, disconnect the cable at the equalizer. Installation Procedure 1. For 25/35 series vehicles, connect the cable at the equalizer. 2. For 25/35 series vehicles, enable the park brake cable automatic adjuster. Refer to Enabling the Park Brake Cable Automatic Adjuster. 3. For the 15 series vehicles, connect the rear park brake cables to the equalizer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Guide Replacement > Page 9166 4. Notice: Refer to Fastener Notice in Service Precautions. For the 15 series vehicles, install the nut to the threaded end of the intermediate cable. ^ Tighten the nut to 3.5 Nm (31 inch lbs.). 5. Remove the safety stands and lower the vehicle. 6. Adjust the park brake system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair Parking Brake Lever: Service and Repair Park Brake Release Handle Assembly Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Remove the park brake release lever mounting bolt. 3. Remove the park brake release lever handle from the knee bolster. 4. Remove the MID-bussed electrical center from the bracket. 5. Remove the park brake release cable housing from the pedal assembly. 6. Remove the park brake release cable from the pedal assembly. 7. Note the routing of the cable as you remove the park brake release handle assembly from the vehicle. Installation Procedure 1. Install the park brake release handle assembly to the vehicle. Install the cable using the same routing as the original cable. 2. Install the park brake release cable to the pedal assembly. 3. Install the park brake release cable housing to the pedal assembly. 4. Install the MID-bussed electrical center to the bracket. 5. Install the park brake release lever handle to the knee bolster. 6. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake release lever mounting bolt. ^ Tighten the bolt to 25 Nm (18 ft. lbs.). 7. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair Parking Brake Pedal: Service and Repair Park Brake Pedal Assembly Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Raise and support the vehicle. Refer Vehicle Lifting 3. For all 15 series vehicles, relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer then removing the cables from the equalizer bar. 4. For 25/35 series vehicles, disable the park brake cable automatic adjuster. Refer to Disabling the Park Brake Cable Automatic Adjuster. 5. Remove the safety stands and lower the vehicle. 6. Remove the left side hinge pillar panel. Refer to Trim Panel Replacement - Hinge Pillar in Interior Trim. 7. Remove the MID-bussed electrical center from the bracket. 8. Disconnect the park brake warning lamp connection. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair > Page 9173 9. Disconnect the park brake release cable and housing from the park brake lever. 10. Remove the park brake lever mounting nuts. 11. Disconnect the front park brake cable from the park brake lever. 12. Remove the park brake lever. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair > Page 9174 1. Connect the front park brake cable to the park brake lever. 2. Install the park brake lever. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake lever mounting nuts. ^ Tighten the nuts to 25 Nm (18 ft. lbs.). 4. Connect the park brake release cable and housing to the park brake lever. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair > Page 9175 5. Connect the park brake warning lamp connector. 6. Install the MID-bussed electrical center to the bracket. 7. Install the left side hinge pillar panel. Refer to Trim Panel Replacement - Hinge Pillar in Interior Trim. 8. Raise and support the vehicle. Refer Vehicle Lifting 9. For 15 series vehicles, install the park brake cable to the equalizer by pulling down on the park brake cable in front of the equalizer then installing the cable to the equalizer bar. 10. For 25/35 series vehicles, enable the park brake cable automatic adjuster. Refer to Enabling the Park Brake Cable Automatic Adjuster. 11. Remove the safety stands and lower the vehicle. 12. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Recalls for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification Technical Service Bulletin # 05042B Date: 060227 Recall - Parking Brake System Modification Bulletin No.: 05042B Date: February 27, 2006 SAFETY Subject: 05042B - PARKING BRAKE SHOE AND DRUM CONTACT Models: 1999-2002 CHEVROLET 1500 SILVERADO 2001-2005 CHEVROLET 2500/3500 SILVERADO, GVWR Greater then or equal to 9200 # 1999-2002 GMC 1500 SIERRA 2001-2005 GMC 2500/3500 SIERRA, GVWR Greater then or equal to 9200 # EQUIPPED WITH A MANUAL TRANSMISSION Supercede: STEP 11.2 IN THE SERVICE PROCEDURE FOR THE 2500/3500 SERIES VEHICLES HAS BEEN REVISED. DISCARD ALL COPIES OF BULLETIN 05042A ISSUED JANUARY 2006. Condition General Motors has decided that a detect which relates to motor vehicle safety exists in certain 1999-2002 Chevrolet Silverado and GMC Sierra 1500 Series, and 2001-2005 Chevrolet Silverado and GMC Sierra 2500/3500 Series vehicles equipped with a manual transmission. Some of these vehicles may have a contact condition between the parking brake shoes and parking brake drums when the parking brake is not applied. If this were to occur, the driver may or may not hear an intermittent scraping noise from the rear of the vehicle while driving. This condition could cause parking brake lining wear. If this lining wear is undetected, the parking brake may become ineffective in immobilizing a parked vehicle on a grade. An ineffective parking brake may result in a vehicle crash. Correction 1500 Series - Dealers are to inspect the parking brake lining thickness on both rear brakes, and depending on the amount of lining remaining, install either a reduced-force parking brake retainer spring clip on both rear brakes or parking brake shoe kits, which includes the reduced-force clips. 2500-3500 Series - Dealers are to inspect the parking brake lining thickness on both rear brakes and install a new rear right-hand parking brake cable assembly. Also, depending on the amount of lining remaining, install new parking brake shoes (both rear brakes). Vehicles Involved Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Recalls for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9184 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Recalls for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9185 Involved are certain 1999-2002 Chevrolet Silverado and GMC Sierra 1500 Series, and 2001-2005 Chevrolet Silverado and GMC Sierra 2500/3500 Series vehicles equipped with a manual transmission and built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US and Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Recalls for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9186 Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada & Export Customer requests for reimbursement of previously paid repairs to correct the condition covered in this bulletin are to be submitted by August 31, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Recalls for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9187 performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuffle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Claim Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Recalls for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9188 Submit a Product Recall Claim with the information shown. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Recalls for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9189 this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure 1500 Series Vehicles ^ J 46277 Rotor Removal Tool ^ J 6125-B Slide Hammer 1. Raise and suitably support the vehicle. 2. Remove the rear tire and wheel assemblies. 3. Remove the rear caliper bolts on one side. 4. Remove the caliper from the rotor (drum-in-hat) and support. Note: Use J 46277, Rotor Removal Tool, with J 6125-B, Slide Hammer, to remove the rotor from the vehicle. Place J 46277 between the rotor surfaces in the vent section of the rotor. DO NOT place J 46277 on the back side of the rotor surface; it may damage the rotor surface. 5. Remove the rear rotor. 6. Remove the park brake shoe retaining clip (2). 7. Repeat Steps 3 through 6 for the other side. 8. Inspect the parking brake shoe lining (1) thickness in at least 6 places on each side of the vehicle. If the lining thickness is less than 1.5 mm (0.06 in) at any spot, install a new parking brake shoe on both sides. 9. Install a new park brake shoe retaining clip. If the parking brake shoe was replaced in the previous step, the new retaining clip was included in the kit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Recalls for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9190 Tighten Tighten the bolt to 3 N.m (25 lb in). 10. Grind out the ridge in the drum section of the rotor, if necessary. 11. Adjust the lining-to-drum clearance at the rear wheel to 0.6604 mm (0.026 in). 12. Install the rotor. 13. Install the caliper to the rotor. 14. Perform the following procedure before installing the caliper guide pin bolts. 14.1. Remove all traces of the original adhesive patch. 14.2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 14.3. Apply Threadlocker, GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 15. Install the caliper bolts. Tighten Tighten the caliper guide pin bolts to 42 N.m (31 lb ft). 16. Repeat Steps 9 through 13 for the other rear caliper. 17. Install the tire and wheel assemblies. Note: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel studs, nuts, or mounting surface, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in a wheel, nut, and/or stud damage. Important: Tighten the nuts evenly and alternately in order to avoid excessive run out. 18. Install the wheel nuts. Tighten Tighten the wheel nuts as shown to 190 N.m (140 lb ft). 19. Lower the vehicle. 2500/3500 Series Vehicles ^ J 46277 Rotor Removal Tool ^ J 6125-B Slide Hammer ^ J 2222-C Wheel Bearing Nut Wrench, or equivalent Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Recalls for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9191 ^ J 8092 Universal Driver Handle - 3/4 inch - 10 ^ J 44420 Differential Bearing and Hub Seal Installer 1. Hold the park brake activation pedal in the FULL upward position. 2. Pull rearward on the front park brake cable until the pedal drum (2) reaches its full reset position. 3. Insert a scribe or the shaft of a thin screwdriver (1) on an upward angle through the hole in the front of the pedal assembly, past the retracted pedal drum, and into the hole in the back of the pedal assembly (3). 4. Slowly release the cable. 5. Raise and suitably support the vehicle. 6. Remove the rear tire and wheels assemblies. 7. Remove the rear caliper bolts on one side. 8. Remove the caliper from the rotor (drum-in-hat) and support. Do not leave the caliper hanging from the hydraulic lines. Note: Use J 46277 Rotor Removal Tool with J 6125-B Slide Hammer to remove the rotor from the vehicle. Place J 46277 between the rotor surfaces in the vent section of the rotor. DO NOT place J 46277 on the back side of the rotor surface; it may damage the rotor surface. 9. For non dual rear wheels: Remove the rear rotor. For dual rear wheels: Perform Steps 12 through 16 before Step 10. 10. Repeat Steps 7 through 9 for the other side of the vehicle. 11. Inspect the parking brake shoe lining thickness in at least 6 places on each side of the vehicle. 11.1. If the lining thickness is less than 1.5 mm (0.06 in) at any spot, install new parking brake shoes on both sides of the vehicle. ^ Non dual rear wheels: Continue to Step 12. ^ Dual rear wheels: Continue to Step 17. 11.2. If the lining thickness is more that 1.5 mm (0.06 in) in all spots, new parking brake shoes are not necessary. ^ Non dual rear wheels: Perform Steps 25 and 26, and then go to Step 38. ^ Dual rear wheels: Continue to Step 25. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Recalls for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9192 12. Remove the axle shaft bolts and axle shaft. 12.1. Remove the flange bolts. 12.2. Lightly tap the axle shaft with a soft-faced hammer in order to loosen the shaft. 12.3. Grip the rib on the axle shaft flange with a pair of locking pliers. Twist the axle shaft flange in order to start the axle shaft removal 12.4. Remove the axle shaft from the tube. 12.5. Remove the gasket 12.6. Clean the axle shaft flange and the outside face of the hub assembly. 13. Remove the axle nut retaining ring. 14. Remove the key. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Recalls for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9193 15. Remove the adjusting nut using the J 2222-C. 16. Remove the hub from the axle housing. 17. Remove the park brake shoe return spring (6). 18. Remove the park brake shoe anchor springs and pins (3). 19. Separate the tips of the shoes from the park brake actuator and remove the park brake shoes (2) and adjuster assembly (5) from the vehicle. 20. Clean the debris and the dust from the park brake components using a clean shop cloth. 21. Install the adjuster assembly to the park brake shoes. 22. Separate the tips of the shoes and install the park brake shoes to the park brake actuator. 23. Install the park brake shoe anchor springs and pins. 24. Install the park brake shoe return spring (6). 25. Grind out the ridge in drum section of rotor if necessary. 26. Adjust the lining-to-drum clearance at the rear wheel to 0.6604 mm (.026 in). 27. Replace the hub seal using the J 44420, differential bearing and hub seal installer (2) and the J 8092, universal driver handle (1). 28. Install the hub to the axle housing. 29. Install and tighten the wheel bearing adjusting nut using the J 2222-C. Rotate the hub in the opposite direction to the way the adjuster nut is turning. Ensure that the inner bearing and the seal seats against the spindle shoulder. Tighten Tighten the adjusting nut to 70 N.m (52 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Recalls for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9194 30. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 31. Turn the adjusting nut clockwise until the nut contacts the bearing cone. The torque on the nut must be zero to finger tight. 32. Insert the adjusting nut lock key into the keyway using one of the following procedures. 32.1. If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. Important: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. 32.2. If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. 33. Install the retaining ring. 34. Install the gasket and the axle shaft into the axle tube. 35. Ensure that the shaft splines mesh into the differential side gear. 36. Align the holes in the axle flange and the gasket with the holes in the hub. Note: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 37. Install the axle flange bolts. Tighten ^ For the 10.5 inch axle, tighten the rear axle flange bolts to 156 N.m (115 lb ft). ^ For the 11.5 inch axle, tighten the rear axle flange bolts to 200 N.m (148 lb ft). 38. Install the rotor. 39. Perform the following procedure before installing the brake caliper mounting bracket bolts: 39.1 Remove all traces of the original adhesive patch. 39.2 Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 39.3 Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 40. Install the brake caliper assembly and bolts. Tighten the brake caliper mounting bracket bolts to ^ RPO JC5/JH5 to 200 N.m (148 lb ft) ^ RPO JH6 to 165 N.m (122 lb ft) ^ RPO JH7 to 300 N.m (221 lb ft) 41. Repeat this procedure for other side starting with Step 11. 42. Disconnect the cable for the right rear from the equalizer. 43. Remove the bolt from the rear axle clip. 44. Remove the cable from the differential clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Recalls for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9195 45. Perform the following procedure to remove the cable (2) from the backing plate (4): 45.1 Compress the spring (3) by pushing towards the lever (1). 45.2 Depress the locking tabs. 45.3 Pull the cable housing out of the backing plate (4). 45.4 Remove the cable (2) through the slot in the backing plate. 46. Remove the park brake cable (2) from the lever (1). 47. Remove the cable from the vehicle. 48. Install the new cable to the vehicle. 49. Install the park brake cable (2) to the lever (1). 50. Perform the following procedure to install the cable (2) to the backing plate (4): 50.1 Compress the spring (3) by pushing towards the lever (1). 50.2 Route the cable (2) through the slot in the backing plate. 50.3 Push the cable housing into the backing plate (4) until the locking tabs snap into place. 51. Bolt the cable to the differential clips. Tighten Tighten the bolt to 25 N.m (18 lb ft). Important: After installing the cable to the rear axle holding clip, verify that the clip is securely retaining the cable. If not, crimp the clip by hand, taking care not to pinch or kink the cable. 52. Install the cable to the differential clip. 53. Connect the cable at the equalizer. 54. Install the wheels and tires. 55. Hold the park brake pedal in the FULL upward position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Recalls for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9196 56. Pull rearward on the front park brake cable until the tension is released from the scribe or nail (1) installed through the holes in the pedal assembly. 57. Remove the scribe or screwdriver (1). 58. Slowly release the park brake cable until it returns to its original position. 59. Release the park brake pedal. Note: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel studs, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage. 60. Install the tire and wheel. 61. Install the wheel nuts. Tighten Tighten the wheel nuts as shown to 190 N.m (140 lb ft). 62. Install the wheel center cap. 63. Lower the vehicle. 64. Apply and release the park brake pedal to ensure that there is no binding or sticking. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Recalls for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9197 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Recalls for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9198 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Recalls for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9199 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification Technical Service Bulletin # 05042B Date: 060227 Recall - Parking Brake System Modification Bulletin No.: 05042B Date: February 27, 2006 SAFETY Subject: 05042B - PARKING BRAKE SHOE AND DRUM CONTACT Models: 1999-2002 CHEVROLET 1500 SILVERADO 2001-2005 CHEVROLET 2500/3500 SILVERADO, GVWR Greater then or equal to 9200 # 1999-2002 GMC 1500 SIERRA 2001-2005 GMC 2500/3500 SIERRA, GVWR Greater then or equal to 9200 # EQUIPPED WITH A MANUAL TRANSMISSION Supercede: STEP 11.2 IN THE SERVICE PROCEDURE FOR THE 2500/3500 SERIES VEHICLES HAS BEEN REVISED. DISCARD ALL COPIES OF BULLETIN 05042A ISSUED JANUARY 2006. Condition General Motors has decided that a detect which relates to motor vehicle safety exists in certain 1999-2002 Chevrolet Silverado and GMC Sierra 1500 Series, and 2001-2005 Chevrolet Silverado and GMC Sierra 2500/3500 Series vehicles equipped with a manual transmission. Some of these vehicles may have a contact condition between the parking brake shoes and parking brake drums when the parking brake is not applied. If this were to occur, the driver may or may not hear an intermittent scraping noise from the rear of the vehicle while driving. This condition could cause parking brake lining wear. If this lining wear is undetected, the parking brake may become ineffective in immobilizing a parked vehicle on a grade. An ineffective parking brake may result in a vehicle crash. Correction 1500 Series - Dealers are to inspect the parking brake lining thickness on both rear brakes, and depending on the amount of lining remaining, install either a reduced-force parking brake retainer spring clip on both rear brakes or parking brake shoe kits, which includes the reduced-force clips. 2500-3500 Series - Dealers are to inspect the parking brake lining thickness on both rear brakes and install a new rear right-hand parking brake cable assembly. Also, depending on the amount of lining remaining, install new parking brake shoes (both rear brakes). Vehicles Involved Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9205 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9206 Involved are certain 1999-2002 Chevrolet Silverado and GMC Sierra 1500 Series, and 2001-2005 Chevrolet Silverado and GMC Sierra 2500/3500 Series vehicles equipped with a manual transmission and built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US and Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9207 Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada & Export Customer requests for reimbursement of previously paid repairs to correct the condition covered in this bulletin are to be submitted by August 31, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9208 performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuffle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Claim Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9209 Submit a Product Recall Claim with the information shown. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9210 this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure 1500 Series Vehicles ^ J 46277 Rotor Removal Tool ^ J 6125-B Slide Hammer 1. Raise and suitably support the vehicle. 2. Remove the rear tire and wheel assemblies. 3. Remove the rear caliper bolts on one side. 4. Remove the caliper from the rotor (drum-in-hat) and support. Note: Use J 46277, Rotor Removal Tool, with J 6125-B, Slide Hammer, to remove the rotor from the vehicle. Place J 46277 between the rotor surfaces in the vent section of the rotor. DO NOT place J 46277 on the back side of the rotor surface; it may damage the rotor surface. 5. Remove the rear rotor. 6. Remove the park brake shoe retaining clip (2). 7. Repeat Steps 3 through 6 for the other side. 8. Inspect the parking brake shoe lining (1) thickness in at least 6 places on each side of the vehicle. If the lining thickness is less than 1.5 mm (0.06 in) at any spot, install a new parking brake shoe on both sides. 9. Install a new park brake shoe retaining clip. If the parking brake shoe was replaced in the previous step, the new retaining clip was included in the kit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9211 Tighten Tighten the bolt to 3 N.m (25 lb in). 10. Grind out the ridge in the drum section of the rotor, if necessary. 11. Adjust the lining-to-drum clearance at the rear wheel to 0.6604 mm (0.026 in). 12. Install the rotor. 13. Install the caliper to the rotor. 14. Perform the following procedure before installing the caliper guide pin bolts. 14.1. Remove all traces of the original adhesive patch. 14.2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 14.3. Apply Threadlocker, GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 15. Install the caliper bolts. Tighten Tighten the caliper guide pin bolts to 42 N.m (31 lb ft). 16. Repeat Steps 9 through 13 for the other rear caliper. 17. Install the tire and wheel assemblies. Note: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel studs, nuts, or mounting surface, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in a wheel, nut, and/or stud damage. Important: Tighten the nuts evenly and alternately in order to avoid excessive run out. 18. Install the wheel nuts. Tighten Tighten the wheel nuts as shown to 190 N.m (140 lb ft). 19. Lower the vehicle. 2500/3500 Series Vehicles ^ J 46277 Rotor Removal Tool ^ J 6125-B Slide Hammer ^ J 2222-C Wheel Bearing Nut Wrench, or equivalent Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9212 ^ J 8092 Universal Driver Handle - 3/4 inch - 10 ^ J 44420 Differential Bearing and Hub Seal Installer 1. Hold the park brake activation pedal in the FULL upward position. 2. Pull rearward on the front park brake cable until the pedal drum (2) reaches its full reset position. 3. Insert a scribe or the shaft of a thin screwdriver (1) on an upward angle through the hole in the front of the pedal assembly, past the retracted pedal drum, and into the hole in the back of the pedal assembly (3). 4. Slowly release the cable. 5. Raise and suitably support the vehicle. 6. Remove the rear tire and wheels assemblies. 7. Remove the rear caliper bolts on one side. 8. Remove the caliper from the rotor (drum-in-hat) and support. Do not leave the caliper hanging from the hydraulic lines. Note: Use J 46277 Rotor Removal Tool with J 6125-B Slide Hammer to remove the rotor from the vehicle. Place J 46277 between the rotor surfaces in the vent section of the rotor. DO NOT place J 46277 on the back side of the rotor surface; it may damage the rotor surface. 9. For non dual rear wheels: Remove the rear rotor. For dual rear wheels: Perform Steps 12 through 16 before Step 10. 10. Repeat Steps 7 through 9 for the other side of the vehicle. 11. Inspect the parking brake shoe lining thickness in at least 6 places on each side of the vehicle. 11.1. If the lining thickness is less than 1.5 mm (0.06 in) at any spot, install new parking brake shoes on both sides of the vehicle. ^ Non dual rear wheels: Continue to Step 12. ^ Dual rear wheels: Continue to Step 17. 11.2. If the lining thickness is more that 1.5 mm (0.06 in) in all spots, new parking brake shoes are not necessary. ^ Non dual rear wheels: Perform Steps 25 and 26, and then go to Step 38. ^ Dual rear wheels: Continue to Step 25. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9213 12. Remove the axle shaft bolts and axle shaft. 12.1. Remove the flange bolts. 12.2. Lightly tap the axle shaft with a soft-faced hammer in order to loosen the shaft. 12.3. Grip the rib on the axle shaft flange with a pair of locking pliers. Twist the axle shaft flange in order to start the axle shaft removal 12.4. Remove the axle shaft from the tube. 12.5. Remove the gasket 12.6. Clean the axle shaft flange and the outside face of the hub assembly. 13. Remove the axle nut retaining ring. 14. Remove the key. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9214 15. Remove the adjusting nut using the J 2222-C. 16. Remove the hub from the axle housing. 17. Remove the park brake shoe return spring (6). 18. Remove the park brake shoe anchor springs and pins (3). 19. Separate the tips of the shoes from the park brake actuator and remove the park brake shoes (2) and adjuster assembly (5) from the vehicle. 20. Clean the debris and the dust from the park brake components using a clean shop cloth. 21. Install the adjuster assembly to the park brake shoes. 22. Separate the tips of the shoes and install the park brake shoes to the park brake actuator. 23. Install the park brake shoe anchor springs and pins. 24. Install the park brake shoe return spring (6). 25. Grind out the ridge in drum section of rotor if necessary. 26. Adjust the lining-to-drum clearance at the rear wheel to 0.6604 mm (.026 in). 27. Replace the hub seal using the J 44420, differential bearing and hub seal installer (2) and the J 8092, universal driver handle (1). 28. Install the hub to the axle housing. 29. Install and tighten the wheel bearing adjusting nut using the J 2222-C. Rotate the hub in the opposite direction to the way the adjuster nut is turning. Ensure that the inner bearing and the seal seats against the spindle shoulder. Tighten Tighten the adjusting nut to 70 N.m (52 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9215 30. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 31. Turn the adjusting nut clockwise until the nut contacts the bearing cone. The torque on the nut must be zero to finger tight. 32. Insert the adjusting nut lock key into the keyway using one of the following procedures. 32.1. If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. Important: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. 32.2. If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. 33. Install the retaining ring. 34. Install the gasket and the axle shaft into the axle tube. 35. Ensure that the shaft splines mesh into the differential side gear. 36. Align the holes in the axle flange and the gasket with the holes in the hub. Note: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 37. Install the axle flange bolts. Tighten ^ For the 10.5 inch axle, tighten the rear axle flange bolts to 156 N.m (115 lb ft). ^ For the 11.5 inch axle, tighten the rear axle flange bolts to 200 N.m (148 lb ft). 38. Install the rotor. 39. Perform the following procedure before installing the brake caliper mounting bracket bolts: 39.1 Remove all traces of the original adhesive patch. 39.2 Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 39.3 Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 40. Install the brake caliper assembly and bolts. Tighten the brake caliper mounting bracket bolts to ^ RPO JC5/JH5 to 200 N.m (148 lb ft) ^ RPO JH6 to 165 N.m (122 lb ft) ^ RPO JH7 to 300 N.m (221 lb ft) 41. Repeat this procedure for other side starting with Step 11. 42. Disconnect the cable for the right rear from the equalizer. 43. Remove the bolt from the rear axle clip. 44. Remove the cable from the differential clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9216 45. Perform the following procedure to remove the cable (2) from the backing plate (4): 45.1 Compress the spring (3) by pushing towards the lever (1). 45.2 Depress the locking tabs. 45.3 Pull the cable housing out of the backing plate (4). 45.4 Remove the cable (2) through the slot in the backing plate. 46. Remove the park brake cable (2) from the lever (1). 47. Remove the cable from the vehicle. 48. Install the new cable to the vehicle. 49. Install the park brake cable (2) to the lever (1). 50. Perform the following procedure to install the cable (2) to the backing plate (4): 50.1 Compress the spring (3) by pushing towards the lever (1). 50.2 Route the cable (2) through the slot in the backing plate. 50.3 Push the cable housing into the backing plate (4) until the locking tabs snap into place. 51. Bolt the cable to the differential clips. Tighten Tighten the bolt to 25 N.m (18 lb ft). Important: After installing the cable to the rear axle holding clip, verify that the clip is securely retaining the cable. If not, crimp the clip by hand, taking care not to pinch or kink the cable. 52. Install the cable to the differential clip. 53. Connect the cable at the equalizer. 54. Install the wheels and tires. 55. Hold the park brake pedal in the FULL upward position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9217 56. Pull rearward on the front park brake cable until the tension is released from the scribe or nail (1) installed through the holes in the pedal assembly. 57. Remove the scribe or screwdriver (1). 58. Slowly release the park brake cable until it returns to its original position. 59. Release the park brake pedal. Note: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel studs, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage. 60. Install the tire and wheel. 61. Install the wheel nuts. Tighten Tighten the wheel nuts as shown to 190 N.m (140 lb ft). 62. Install the wheel center cap. 63. Lower the vehicle. 64. Apply and release the park brake pedal to ensure that there is no binding or sticking. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9218 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9219 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Shoe: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9220 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Technical Service Bulletins > Page 9221 Parking Brake Shoe: Adjustments Park Brake Adjustment Park Brake Shoe Adjustment ^ Tools Required J 21177-A Drum-to-Brake Shoe Clearance Gage Caution: Refer to Brake Dust Caution in Service Precautions. Important: The park brake shoes must be adjusted before the park brake pedal is adjusted. 1. Set the J 21177-A so that it contacts the inside diameter of the rotor. 2. Position the J 21177-A over the shoe and the lining at the widest point. 3. Turn the adjuster nut until the lining just contacts the J 21177-A. 4. Repeat steps 1-3 for the opposite side. 5. The clearance between the park brake shoe and the rotor is 0.6604 mm (0.026 inch). Park Brake Pedal Adjustment Important: Before you adjust the park brake, verify that the park brake shoes are adjusted to provide a clearance of 0.6604 mm (0.026 inch). 1. Verify that the self adjuster lock-out pin has be removed. 2. Fully apply and release the park brake pedal 3 times. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Parking Brake Shoe Replacement (Except RPO NYS, 1500HD, 25/35 Series) Parking Brake Shoe: Service and Repair Parking Brake Shoe Replacement (Except RPO NYS, 1500HD, 25/35 Series) Parking Brake Shoe Replacement (Except RPO NYS, 1500HD, 25/35 Series) Removal Procedure Caution: Avoid taking the following actions when you service wheel brake parts: - Do not grind brake linings. - Do not sand brake linings. - Do not clean wheel brake parts with a dry brush or with compressed air. Some models or aftermarket brake parts may contain asbestos fibers which can become airborne in dust. Breathing dust with asbestos fibers may cause serious bodily harm. Use a water-dampened cloth in order to remove any dust on brake parts. Equipment is available commercially in order to perform this washing function. These wet methods prevent fibers from becoming airborne. 1. Raise and support the vehicle. 2. Remove the tire and the wheel. 3. Relieve the tension on the park brake cables by loosening the nut at the equalizer. 4. Remove the park brake cable from the park brake actuator lever. 5. Remove the rotor. Refer to Rear Brake Rotor Replacement in Disc Brakes See: Disc Brake System/Brake Rotor/Disc/Service and Repair. 6. Turn the adjustment screw (1) to the fully home position in the notched adjustment nut. 7. Remove the park brake shoe assembly from the backing plate by removing the tips from the slots and sliding the shoe (2) towards the retaining spring (3) until the shoe disengages from the spring. 8. Remove the park brake shoe assembly from the vehicle by placing one of the open ends of the shoe over the axle flange and rotating the shoe until it has cleared the flange. Installation Procedure 1. Clean the debris and the dust from the park brake components using a clean shop cloth. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Parking Brake Shoe Replacement (Except RPO NYS, 1500HD, 25/35 Series) > Page 9224 2. Align the slots in both the adjusting screw (1) and tappet to be parallel with the backing plate face. 3. Install the park brake shoe assembly to the vehicle by placing one of the open ends of the shoe (2) over the axle flange and rotating the shoe until it is behind the flange. 4. Position the park brake shoe (2) on the inboard side of the actuator. 5. Slide the park brake shoe (2) into position and seat into the retaining spring (3). 6. Inspect the shoe assembly position. The shoe must be central on the backing plate with both tips located in the slots. 7. Adjust the park brake shoe. Refer to Park Brake Adjustment See: Adjustments. 8. Install the rotor. Refer to Rear Brake Rotor Replacement in Disc Brakes See: Disc Brake System/Brake Rotor/Disc/Service and Repair. 9. Install the park brake cable to the park brake actuator lever. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 10. Tighten the nut to the intermediate cable at the equalizer. Tighten Tighten the nut to 3.5 Nm (31 lb in). 11. Install the tire and wheel. 12. Remove the safety stands. 13. Lower the vehicle. 14. Adjust park brake cable. Refer to Park Brake Adjustment See: Adjustments. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Parking Brake Shoe Replacement (Except RPO NYS, 1500HD, 25/35 Series) > Page 9225 Parking Brake Shoe: Service and Repair Parking Brake Shoe Replacement (RPO NYS) Parking Brake Shoe Replacement (RPO NYS) Removal Procedure Caution: Avoid taking the following actions when you service wheel brake parts: - Do not grind brake linings. - Do not sand brake linings. - Do not clean wheel brake parts with a dry brush or with compressed air. Some models or aftermarket brake parts may contain asbestos fibers which can become airborne in dust. Breathing dust with asbestos fibers may cause serious bodily harm. Use a water-dampened cloth in order to remove any dust on brake parts. Equipment is available commercially in order to perform this washing function. These wet methods prevent fibers from becoming airborne. 1. Release the park brake. 2. Raise and support the vehicle. 3. Remove the tire and wheel assembly. 4. Relieve the tension from the park brake cable by pulling down on the intermediate cable then release the cable from the equalizer bar. 5. Remove the rear park brake bracket bolt. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Parking Brake Shoe Replacement (Except RPO NYS, 1500HD, 25/35 Series) > Page 9226 6. Remove the park brake cable from the park brake actuator lever. 7. Remove the wheel bearing. Refer to Wheel Hub and Bearing Replacement in Rear Wheel Steering See: Maintenance/Wheels and Tires/Wheel Hub/Service and Repair. 8. Remove the park brake shoe from the backing plate. Installation Procedure 1. Install the park brake shoe to the backing plate. 2. Install the wheel bearing. Refer to Wheel Hub and Bearing Replacement in Rear Wheel Steering See: Maintenance/Wheels and Tires/Wheel Hub/Service and Repair. 3. Adjust the park brake shoe. Refer to Park Brake Adjustment in Park Brake See: Adjustments. 4. Install the park brake cable to the park brake actuator lever. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Parking Brake Shoe Replacement (Except RPO NYS, 1500HD, 25/35 Series) > Page 9227 damage to parts and systems. 5. Install the rear park brake bracket bolt. Tighten Tighten the bolt to 61 Nm (45 lb ft). 6. Install the park brake cable to the equalizer bar. 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. Adjust the park brake cable. Refer to Park Brake Adjustment See: Adjustments. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Parking Brake Shoe Replacement (Except RPO NYS, 1500HD, 25/35 Series) > Page 9228 Parking Brake Shoe: Service and Repair Parking Brake Shoe Replacement (1500HD/25/35 Series) Parking Brake Shoe Replacement (1500HD/25/35 Series) Removal Procedure Caution: Avoid taking the following actions when you service wheel brake parts: - Do not grind brake linings. - Do not sand brake linings. - Do not clean wheel brake parts with a dry brush or with compressed air. Some models or aftermarket brake parts may contain asbestos fibers which can become airborne in dust. Breathing dust with asbestos fibers may cause serious bodily harm. Use a water-dampened cloth in order to remove any dust on brake parts. Equipment is available commercially in order to perform this washing function. These wet methods prevent fibers from becoming airborne. 1. For the 1500HD, relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer then removing the cable from the equalizer bar. 2. For the 25/35 series Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling See: Parking Brake Cable/Adjustments. 3. Raise and support the vehicle. 4. Remove the tire and the wheel. 5. Perform the following procedure to remove the cable (2) from the backing plate (4): 5.1. Compress the spring (3) by pushing towards the lever (1). 5.2. Depress the locking tabs. 5.3. Pull the cable housing out of the backing plate (4). 5.4. Remove the cable (2) through the slot in the backing plate. 6. Remove the park brake cable (2) from the lever (1). 7. Remove the rotor. Refer to Rear Brake Rotor Replacement in Disc Brakes See: Disc Brake System/Brake Rotor/Disc/Service and Repair. 8. Remove the rear axle shaft. Refer to Rear Axle Shaft Replacement in Rear Drive Axle . Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Parking Brake Shoe Replacement (Except RPO NYS, 1500HD, 25/35 Series) > Page 9229 9. Remove the park brake shoe return spring (6). 10. Remove the park brake shoe anchor springs and pins. 11. Separate the tips of the shoes from the park brake actuator and remove the park brake shoes and adjuster assembly from the vehicle. Installation Procedure 1. Clean the debris and the dust from the park brake components using a clean shop cloth. 2. Install the adjuster assembly to the park brake shoes. 3. Separate the tips of the shoes and install the park brake shoes to the park brake actuator. 4. Install the park brake shoe anchor springs and pins. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Parking Brake Shoe Replacement (Except RPO NYS, 1500HD, 25/35 Series) > Page 9230 5. Install the park brake shoe return spring (6). 6. Adjust the park brake shoe. Refer to Park Brake Adjustment See: Adjustments. 7. Install the rear axle shaft. Refer to Rear Axle Shaft Replacement in Rear Drive Axle . 8. Install the rotor. Refer to Rear Brake Rotor Replacement in Disc Brakes See: Disc Brake System/Brake Rotor/Disc/Service and Repair. 9. Install the park brake cable (2) to the lever (1). 10. Perform the following procedure to install the cable (2) to the backing plate (4): 10.1. Compress the spring (3) by pushing towards the lever (1). 10.2. Route the cable (2) through the slot in the backing plate. 10.3. Push the cable housing into the backing plate (4) until the locking tabs snap into place. 11. Install the tire and wheel. 12. Remove the safety stands. 13. Lower the vehicle. 14. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling See: Parking Brake Cable/Adjustments. 15. For the 1500HD, install the park brake cable to the equalizer by pulling down on the park brake cable in front of the equalizer then installing the cable to the equalizer bar. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Parking Brake Shoe Replacement (Except RPO NYS, 1500HD, 25/35 Series) > Page 9231 16. Adjust the park brake cable. Refer to Park Brake Adjustment See: Adjustments. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > Recalls for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification Technical Service Bulletin # 05042B Date: 060227 Recall - Parking Brake System Modification Bulletin No.: 05042B Date: February 27, 2006 SAFETY Subject: 05042B - PARKING BRAKE SHOE AND DRUM CONTACT Models: 1999-2002 CHEVROLET 1500 SILVERADO 2001-2005 CHEVROLET 2500/3500 SILVERADO, GVWR Greater then or equal to 9200 # 1999-2002 GMC 1500 SIERRA 2001-2005 GMC 2500/3500 SIERRA, GVWR Greater then or equal to 9200 # EQUIPPED WITH A MANUAL TRANSMISSION Supercede: STEP 11.2 IN THE SERVICE PROCEDURE FOR THE 2500/3500 SERIES VEHICLES HAS BEEN REVISED. DISCARD ALL COPIES OF BULLETIN 05042A ISSUED JANUARY 2006. Condition General Motors has decided that a detect which relates to motor vehicle safety exists in certain 1999-2002 Chevrolet Silverado and GMC Sierra 1500 Series, and 2001-2005 Chevrolet Silverado and GMC Sierra 2500/3500 Series vehicles equipped with a manual transmission. Some of these vehicles may have a contact condition between the parking brake shoes and parking brake drums when the parking brake is not applied. If this were to occur, the driver may or may not hear an intermittent scraping noise from the rear of the vehicle while driving. This condition could cause parking brake lining wear. If this lining wear is undetected, the parking brake may become ineffective in immobilizing a parked vehicle on a grade. An ineffective parking brake may result in a vehicle crash. Correction 1500 Series - Dealers are to inspect the parking brake lining thickness on both rear brakes, and depending on the amount of lining remaining, install either a reduced-force parking brake retainer spring clip on both rear brakes or parking brake shoe kits, which includes the reduced-force clips. 2500-3500 Series - Dealers are to inspect the parking brake lining thickness on both rear brakes and install a new rear right-hand parking brake cable assembly. Also, depending on the amount of lining remaining, install new parking brake shoes (both rear brakes). Vehicles Involved Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > Recalls for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9240 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > Recalls for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9241 Involved are certain 1999-2002 Chevrolet Silverado and GMC Sierra 1500 Series, and 2001-2005 Chevrolet Silverado and GMC Sierra 2500/3500 Series vehicles equipped with a manual transmission and built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US and Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > Recalls for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9242 Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada & Export Customer requests for reimbursement of previously paid repairs to correct the condition covered in this bulletin are to be submitted by August 31, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > Recalls for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9243 performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuffle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Claim Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > Recalls for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9244 Submit a Product Recall Claim with the information shown. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > Recalls for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9245 this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure 1500 Series Vehicles ^ J 46277 Rotor Removal Tool ^ J 6125-B Slide Hammer 1. Raise and suitably support the vehicle. 2. Remove the rear tire and wheel assemblies. 3. Remove the rear caliper bolts on one side. 4. Remove the caliper from the rotor (drum-in-hat) and support. Note: Use J 46277, Rotor Removal Tool, with J 6125-B, Slide Hammer, to remove the rotor from the vehicle. Place J 46277 between the rotor surfaces in the vent section of the rotor. DO NOT place J 46277 on the back side of the rotor surface; it may damage the rotor surface. 5. Remove the rear rotor. 6. Remove the park brake shoe retaining clip (2). 7. Repeat Steps 3 through 6 for the other side. 8. Inspect the parking brake shoe lining (1) thickness in at least 6 places on each side of the vehicle. If the lining thickness is less than 1.5 mm (0.06 in) at any spot, install a new parking brake shoe on both sides. 9. Install a new park brake shoe retaining clip. If the parking brake shoe was replaced in the previous step, the new retaining clip was included in the kit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > Recalls for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9246 Tighten Tighten the bolt to 3 N.m (25 lb in). 10. Grind out the ridge in the drum section of the rotor, if necessary. 11. Adjust the lining-to-drum clearance at the rear wheel to 0.6604 mm (0.026 in). 12. Install the rotor. 13. Install the caliper to the rotor. 14. Perform the following procedure before installing the caliper guide pin bolts. 14.1. Remove all traces of the original adhesive patch. 14.2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 14.3. Apply Threadlocker, GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 15. Install the caliper bolts. Tighten Tighten the caliper guide pin bolts to 42 N.m (31 lb ft). 16. Repeat Steps 9 through 13 for the other rear caliper. 17. Install the tire and wheel assemblies. Note: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel studs, nuts, or mounting surface, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in a wheel, nut, and/or stud damage. Important: Tighten the nuts evenly and alternately in order to avoid excessive run out. 18. Install the wheel nuts. Tighten Tighten the wheel nuts as shown to 190 N.m (140 lb ft). 19. Lower the vehicle. 2500/3500 Series Vehicles ^ J 46277 Rotor Removal Tool ^ J 6125-B Slide Hammer ^ J 2222-C Wheel Bearing Nut Wrench, or equivalent Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > Recalls for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9247 ^ J 8092 Universal Driver Handle - 3/4 inch - 10 ^ J 44420 Differential Bearing and Hub Seal Installer 1. Hold the park brake activation pedal in the FULL upward position. 2. Pull rearward on the front park brake cable until the pedal drum (2) reaches its full reset position. 3. Insert a scribe or the shaft of a thin screwdriver (1) on an upward angle through the hole in the front of the pedal assembly, past the retracted pedal drum, and into the hole in the back of the pedal assembly (3). 4. Slowly release the cable. 5. Raise and suitably support the vehicle. 6. Remove the rear tire and wheels assemblies. 7. Remove the rear caliper bolts on one side. 8. Remove the caliper from the rotor (drum-in-hat) and support. Do not leave the caliper hanging from the hydraulic lines. Note: Use J 46277 Rotor Removal Tool with J 6125-B Slide Hammer to remove the rotor from the vehicle. Place J 46277 between the rotor surfaces in the vent section of the rotor. DO NOT place J 46277 on the back side of the rotor surface; it may damage the rotor surface. 9. For non dual rear wheels: Remove the rear rotor. For dual rear wheels: Perform Steps 12 through 16 before Step 10. 10. Repeat Steps 7 through 9 for the other side of the vehicle. 11. Inspect the parking brake shoe lining thickness in at least 6 places on each side of the vehicle. 11.1. If the lining thickness is less than 1.5 mm (0.06 in) at any spot, install new parking brake shoes on both sides of the vehicle. ^ Non dual rear wheels: Continue to Step 12. ^ Dual rear wheels: Continue to Step 17. 11.2. If the lining thickness is more that 1.5 mm (0.06 in) in all spots, new parking brake shoes are not necessary. ^ Non dual rear wheels: Perform Steps 25 and 26, and then go to Step 38. ^ Dual rear wheels: Continue to Step 25. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > Recalls for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9248 12. Remove the axle shaft bolts and axle shaft. 12.1. Remove the flange bolts. 12.2. Lightly tap the axle shaft with a soft-faced hammer in order to loosen the shaft. 12.3. Grip the rib on the axle shaft flange with a pair of locking pliers. Twist the axle shaft flange in order to start the axle shaft removal 12.4. Remove the axle shaft from the tube. 12.5. Remove the gasket 12.6. Clean the axle shaft flange and the outside face of the hub assembly. 13. Remove the axle nut retaining ring. 14. Remove the key. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > Recalls for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9249 15. Remove the adjusting nut using the J 2222-C. 16. Remove the hub from the axle housing. 17. Remove the park brake shoe return spring (6). 18. Remove the park brake shoe anchor springs and pins (3). 19. Separate the tips of the shoes from the park brake actuator and remove the park brake shoes (2) and adjuster assembly (5) from the vehicle. 20. Clean the debris and the dust from the park brake components using a clean shop cloth. 21. Install the adjuster assembly to the park brake shoes. 22. Separate the tips of the shoes and install the park brake shoes to the park brake actuator. 23. Install the park brake shoe anchor springs and pins. 24. Install the park brake shoe return spring (6). 25. Grind out the ridge in drum section of rotor if necessary. 26. Adjust the lining-to-drum clearance at the rear wheel to 0.6604 mm (.026 in). 27. Replace the hub seal using the J 44420, differential bearing and hub seal installer (2) and the J 8092, universal driver handle (1). 28. Install the hub to the axle housing. 29. Install and tighten the wheel bearing adjusting nut using the J 2222-C. Rotate the hub in the opposite direction to the way the adjuster nut is turning. Ensure that the inner bearing and the seal seats against the spindle shoulder. Tighten Tighten the adjusting nut to 70 N.m (52 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > Recalls for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9250 30. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 31. Turn the adjusting nut clockwise until the nut contacts the bearing cone. The torque on the nut must be zero to finger tight. 32. Insert the adjusting nut lock key into the keyway using one of the following procedures. 32.1. If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. Important: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. 32.2. If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. 33. Install the retaining ring. 34. Install the gasket and the axle shaft into the axle tube. 35. Ensure that the shaft splines mesh into the differential side gear. 36. Align the holes in the axle flange and the gasket with the holes in the hub. Note: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 37. Install the axle flange bolts. Tighten ^ For the 10.5 inch axle, tighten the rear axle flange bolts to 156 N.m (115 lb ft). ^ For the 11.5 inch axle, tighten the rear axle flange bolts to 200 N.m (148 lb ft). 38. Install the rotor. 39. Perform the following procedure before installing the brake caliper mounting bracket bolts: 39.1 Remove all traces of the original adhesive patch. 39.2 Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 39.3 Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 40. Install the brake caliper assembly and bolts. Tighten the brake caliper mounting bracket bolts to ^ RPO JC5/JH5 to 200 N.m (148 lb ft) ^ RPO JH6 to 165 N.m (122 lb ft) ^ RPO JH7 to 300 N.m (221 lb ft) 41. Repeat this procedure for other side starting with Step 11. 42. Disconnect the cable for the right rear from the equalizer. 43. Remove the bolt from the rear axle clip. 44. Remove the cable from the differential clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > Recalls for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9251 45. Perform the following procedure to remove the cable (2) from the backing plate (4): 45.1 Compress the spring (3) by pushing towards the lever (1). 45.2 Depress the locking tabs. 45.3 Pull the cable housing out of the backing plate (4). 45.4 Remove the cable (2) through the slot in the backing plate. 46. Remove the park brake cable (2) from the lever (1). 47. Remove the cable from the vehicle. 48. Install the new cable to the vehicle. 49. Install the park brake cable (2) to the lever (1). 50. Perform the following procedure to install the cable (2) to the backing plate (4): 50.1 Compress the spring (3) by pushing towards the lever (1). 50.2 Route the cable (2) through the slot in the backing plate. 50.3 Push the cable housing into the backing plate (4) until the locking tabs snap into place. 51. Bolt the cable to the differential clips. Tighten Tighten the bolt to 25 N.m (18 lb ft). Important: After installing the cable to the rear axle holding clip, verify that the clip is securely retaining the cable. If not, crimp the clip by hand, taking care not to pinch or kink the cable. 52. Install the cable to the differential clip. 53. Connect the cable at the equalizer. 54. Install the wheels and tires. 55. Hold the park brake pedal in the FULL upward position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > Recalls for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9252 56. Pull rearward on the front park brake cable until the tension is released from the scribe or nail (1) installed through the holes in the pedal assembly. 57. Remove the scribe or screwdriver (1). 58. Slowly release the park brake cable until it returns to its original position. 59. Release the park brake pedal. Note: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel studs, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage. 60. Install the tire and wheel. 61. Install the wheel nuts. Tighten Tighten the wheel nuts as shown to 190 N.m (140 lb ft). 62. Install the wheel center cap. 63. Lower the vehicle. 64. Apply and release the park brake pedal to ensure that there is no binding or sticking. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > Recalls for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9253 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > Recalls for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9254 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > Recalls for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9255 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification Technical Service Bulletin # 05042B Date: 060227 Recall - Parking Brake System Modification Bulletin No.: 05042B Date: February 27, 2006 SAFETY Subject: 05042B - PARKING BRAKE SHOE AND DRUM CONTACT Models: 1999-2002 CHEVROLET 1500 SILVERADO 2001-2005 CHEVROLET 2500/3500 SILVERADO, GVWR Greater then or equal to 9200 # 1999-2002 GMC 1500 SIERRA 2001-2005 GMC 2500/3500 SIERRA, GVWR Greater then or equal to 9200 # EQUIPPED WITH A MANUAL TRANSMISSION Supercede: STEP 11.2 IN THE SERVICE PROCEDURE FOR THE 2500/3500 SERIES VEHICLES HAS BEEN REVISED. DISCARD ALL COPIES OF BULLETIN 05042A ISSUED JANUARY 2006. Condition General Motors has decided that a detect which relates to motor vehicle safety exists in certain 1999-2002 Chevrolet Silverado and GMC Sierra 1500 Series, and 2001-2005 Chevrolet Silverado and GMC Sierra 2500/3500 Series vehicles equipped with a manual transmission. Some of these vehicles may have a contact condition between the parking brake shoes and parking brake drums when the parking brake is not applied. If this were to occur, the driver may or may not hear an intermittent scraping noise from the rear of the vehicle while driving. This condition could cause parking brake lining wear. If this lining wear is undetected, the parking brake may become ineffective in immobilizing a parked vehicle on a grade. An ineffective parking brake may result in a vehicle crash. Correction 1500 Series - Dealers are to inspect the parking brake lining thickness on both rear brakes, and depending on the amount of lining remaining, install either a reduced-force parking brake retainer spring clip on both rear brakes or parking brake shoe kits, which includes the reduced-force clips. 2500-3500 Series - Dealers are to inspect the parking brake lining thickness on both rear brakes and install a new rear right-hand parking brake cable assembly. Also, depending on the amount of lining remaining, install new parking brake shoes (both rear brakes). Vehicles Involved Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9261 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9262 Involved are certain 1999-2002 Chevrolet Silverado and GMC Sierra 1500 Series, and 2001-2005 Chevrolet Silverado and GMC Sierra 2500/3500 Series vehicles equipped with a manual transmission and built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US and Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9263 Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada & Export Customer requests for reimbursement of previously paid repairs to correct the condition covered in this bulletin are to be submitted by August 31, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9264 performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuffle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Claim Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9265 Submit a Product Recall Claim with the information shown. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9266 this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure 1500 Series Vehicles ^ J 46277 Rotor Removal Tool ^ J 6125-B Slide Hammer 1. Raise and suitably support the vehicle. 2. Remove the rear tire and wheel assemblies. 3. Remove the rear caliper bolts on one side. 4. Remove the caliper from the rotor (drum-in-hat) and support. Note: Use J 46277, Rotor Removal Tool, with J 6125-B, Slide Hammer, to remove the rotor from the vehicle. Place J 46277 between the rotor surfaces in the vent section of the rotor. DO NOT place J 46277 on the back side of the rotor surface; it may damage the rotor surface. 5. Remove the rear rotor. 6. Remove the park brake shoe retaining clip (2). 7. Repeat Steps 3 through 6 for the other side. 8. Inspect the parking brake shoe lining (1) thickness in at least 6 places on each side of the vehicle. If the lining thickness is less than 1.5 mm (0.06 in) at any spot, install a new parking brake shoe on both sides. 9. Install a new park brake shoe retaining clip. If the parking brake shoe was replaced in the previous step, the new retaining clip was included in the kit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9267 Tighten Tighten the bolt to 3 N.m (25 lb in). 10. Grind out the ridge in the drum section of the rotor, if necessary. 11. Adjust the lining-to-drum clearance at the rear wheel to 0.6604 mm (0.026 in). 12. Install the rotor. 13. Install the caliper to the rotor. 14. Perform the following procedure before installing the caliper guide pin bolts. 14.1. Remove all traces of the original adhesive patch. 14.2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 14.3. Apply Threadlocker, GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 15. Install the caliper bolts. Tighten Tighten the caliper guide pin bolts to 42 N.m (31 lb ft). 16. Repeat Steps 9 through 13 for the other rear caliper. 17. Install the tire and wheel assemblies. Note: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel studs, nuts, or mounting surface, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in a wheel, nut, and/or stud damage. Important: Tighten the nuts evenly and alternately in order to avoid excessive run out. 18. Install the wheel nuts. Tighten Tighten the wheel nuts as shown to 190 N.m (140 lb ft). 19. Lower the vehicle. 2500/3500 Series Vehicles ^ J 46277 Rotor Removal Tool ^ J 6125-B Slide Hammer ^ J 2222-C Wheel Bearing Nut Wrench, or equivalent Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9268 ^ J 8092 Universal Driver Handle - 3/4 inch - 10 ^ J 44420 Differential Bearing and Hub Seal Installer 1. Hold the park brake activation pedal in the FULL upward position. 2. Pull rearward on the front park brake cable until the pedal drum (2) reaches its full reset position. 3. Insert a scribe or the shaft of a thin screwdriver (1) on an upward angle through the hole in the front of the pedal assembly, past the retracted pedal drum, and into the hole in the back of the pedal assembly (3). 4. Slowly release the cable. 5. Raise and suitably support the vehicle. 6. Remove the rear tire and wheels assemblies. 7. Remove the rear caliper bolts on one side. 8. Remove the caliper from the rotor (drum-in-hat) and support. Do not leave the caliper hanging from the hydraulic lines. Note: Use J 46277 Rotor Removal Tool with J 6125-B Slide Hammer to remove the rotor from the vehicle. Place J 46277 between the rotor surfaces in the vent section of the rotor. DO NOT place J 46277 on the back side of the rotor surface; it may damage the rotor surface. 9. For non dual rear wheels: Remove the rear rotor. For dual rear wheels: Perform Steps 12 through 16 before Step 10. 10. Repeat Steps 7 through 9 for the other side of the vehicle. 11. Inspect the parking brake shoe lining thickness in at least 6 places on each side of the vehicle. 11.1. If the lining thickness is less than 1.5 mm (0.06 in) at any spot, install new parking brake shoes on both sides of the vehicle. ^ Non dual rear wheels: Continue to Step 12. ^ Dual rear wheels: Continue to Step 17. 11.2. If the lining thickness is more that 1.5 mm (0.06 in) in all spots, new parking brake shoes are not necessary. ^ Non dual rear wheels: Perform Steps 25 and 26, and then go to Step 38. ^ Dual rear wheels: Continue to Step 25. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9269 12. Remove the axle shaft bolts and axle shaft. 12.1. Remove the flange bolts. 12.2. Lightly tap the axle shaft with a soft-faced hammer in order to loosen the shaft. 12.3. Grip the rib on the axle shaft flange with a pair of locking pliers. Twist the axle shaft flange in order to start the axle shaft removal 12.4. Remove the axle shaft from the tube. 12.5. Remove the gasket 12.6. Clean the axle shaft flange and the outside face of the hub assembly. 13. Remove the axle nut retaining ring. 14. Remove the key. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9270 15. Remove the adjusting nut using the J 2222-C. 16. Remove the hub from the axle housing. 17. Remove the park brake shoe return spring (6). 18. Remove the park brake shoe anchor springs and pins (3). 19. Separate the tips of the shoes from the park brake actuator and remove the park brake shoes (2) and adjuster assembly (5) from the vehicle. 20. Clean the debris and the dust from the park brake components using a clean shop cloth. 21. Install the adjuster assembly to the park brake shoes. 22. Separate the tips of the shoes and install the park brake shoes to the park brake actuator. 23. Install the park brake shoe anchor springs and pins. 24. Install the park brake shoe return spring (6). 25. Grind out the ridge in drum section of rotor if necessary. 26. Adjust the lining-to-drum clearance at the rear wheel to 0.6604 mm (.026 in). 27. Replace the hub seal using the J 44420, differential bearing and hub seal installer (2) and the J 8092, universal driver handle (1). 28. Install the hub to the axle housing. 29. Install and tighten the wheel bearing adjusting nut using the J 2222-C. Rotate the hub in the opposite direction to the way the adjuster nut is turning. Ensure that the inner bearing and the seal seats against the spindle shoulder. Tighten Tighten the adjusting nut to 70 N.m (52 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9271 30. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 31. Turn the adjusting nut clockwise until the nut contacts the bearing cone. The torque on the nut must be zero to finger tight. 32. Insert the adjusting nut lock key into the keyway using one of the following procedures. 32.1. If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. Important: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. 32.2. If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. 33. Install the retaining ring. 34. Install the gasket and the axle shaft into the axle tube. 35. Ensure that the shaft splines mesh into the differential side gear. 36. Align the holes in the axle flange and the gasket with the holes in the hub. Note: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 37. Install the axle flange bolts. Tighten ^ For the 10.5 inch axle, tighten the rear axle flange bolts to 156 N.m (115 lb ft). ^ For the 11.5 inch axle, tighten the rear axle flange bolts to 200 N.m (148 lb ft). 38. Install the rotor. 39. Perform the following procedure before installing the brake caliper mounting bracket bolts: 39.1 Remove all traces of the original adhesive patch. 39.2 Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. 39.3 Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. 40. Install the brake caliper assembly and bolts. Tighten the brake caliper mounting bracket bolts to ^ RPO JC5/JH5 to 200 N.m (148 lb ft) ^ RPO JH6 to 165 N.m (122 lb ft) ^ RPO JH7 to 300 N.m (221 lb ft) 41. Repeat this procedure for other side starting with Step 11. 42. Disconnect the cable for the right rear from the equalizer. 43. Remove the bolt from the rear axle clip. 44. Remove the cable from the differential clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9272 45. Perform the following procedure to remove the cable (2) from the backing plate (4): 45.1 Compress the spring (3) by pushing towards the lever (1). 45.2 Depress the locking tabs. 45.3 Pull the cable housing out of the backing plate (4). 45.4 Remove the cable (2) through the slot in the backing plate. 46. Remove the park brake cable (2) from the lever (1). 47. Remove the cable from the vehicle. 48. Install the new cable to the vehicle. 49. Install the park brake cable (2) to the lever (1). 50. Perform the following procedure to install the cable (2) to the backing plate (4): 50.1 Compress the spring (3) by pushing towards the lever (1). 50.2 Route the cable (2) through the slot in the backing plate. 50.3 Push the cable housing into the backing plate (4) until the locking tabs snap into place. 51. Bolt the cable to the differential clips. Tighten Tighten the bolt to 25 N.m (18 lb ft). Important: After installing the cable to the rear axle holding clip, verify that the clip is securely retaining the cable. If not, crimp the clip by hand, taking care not to pinch or kink the cable. 52. Install the cable to the differential clip. 53. Connect the cable at the equalizer. 54. Install the wheels and tires. 55. Hold the park brake pedal in the FULL upward position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9273 56. Pull rearward on the front park brake cable until the tension is released from the scribe or nail (1) installed through the holes in the pedal assembly. 57. Remove the scribe or screwdriver (1). 58. Slowly release the park brake cable until it returns to its original position. 59. Release the park brake pedal. Note: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel studs, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage. 60. Install the tire and wheel. 61. Install the wheel nuts. Tighten Tighten the wheel nuts as shown to 190 N.m (140 lb ft). 62. Install the wheel center cap. 63. Lower the vehicle. 64. Apply and release the park brake pedal to ensure that there is no binding or sticking. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9274 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9275 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Tensioner: > 05042B > Feb > 06 > Recall - Parking Brake System Modification > Page 9276 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Remove the MID-bussed electrical center from the bracket. 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch mounting bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Service and Repair > Page 9280 1. Install the park brake warning lamp switch. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake warning lamp switch mounting bolt. ^ Tighten the bolt to 3 Nm (25 inch lbs.). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the MID-bussed electrical center to the bracket. 5. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking Technical Service Bulletin # 05006 Date: 050323 Recall - Brake Booster Pressure Accumulator Cracking Product Safety - Hydro-Boost Accumulator Over-Pressurization # 05006 - (Mar 23, 2005) Models: 2004 Chevrolet Kodiak 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban 2004 GMC TopKick 2004-2005 GMC Savana, Sierra, Yukon XL Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Yukon XL vehicles. On some of these vehicles, the hydraulic brake booster's pressure accumulator may crack and/or separate from the Hydro-Boost(R) assembly during normal vehicle operating conditions. If a separation were to occur and the hood of the vehicle were open, fragments from the accumulator could cause injury to people in the immediate area. In addition, the presence of this crack or fractured surface could allow the hydraulic fluid to leak from the accumulator circuit of the booster assembly. The loss of fluid would cause increased steering and braking effort. Correction Dealers are to inspect the hydraulic brake booster, and replace it if necessary. Vehicles Involved Involved are certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9290 Yukon XL vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information A very small number of vehicles (less than 90 world-wide) will require the replacement of the hydraulic brake booster. Do not order boosters for shelf stock. When a replacement is required, order the appropriate booster from GMSPO. All replaced boosters (excluding Export) must be returned to the Warranty Parts Center. Hold the booster until you receive the request for return. Special Tool Beginning February 18, 2005, each dealer was shipped a Hydro-Boost Checking Tool, CH 47950, for use in this recall. This tool is being furnished at no charge. Additional tools, if required, may be purchased by contacting SPX Kent-Moore at 1-800-468-6657. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9291 Claim Information Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification -- For Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- For US and Export (US States, Territories and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9292 of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Inspection Tools Required CH 47950 Hydro-Boost Checking Tool 1. With the vehicle transmission in PARK or NEUTRAL, set the park brake. 2. With the engine OFF, make a minimum of five (5) high effort brake applies until the pedal feels hard. 3. Start the engine. Important: DO NOT depress the brake pedal until instructed. 4. Turn the steering wheel to the "steering lock" (fully turned) position. Hold at the steering lock position for 1 to 2 seconds and then release the steering wheel. Repeat a total of 3 times. 5. Turn the vehicle off being careful not to step on the brake pedal. 6. For Express/Savana only: A. Remove the remote power steering reservoir mounting nuts. B. Disconnect the reservoir outlet hose from the booster unit. Keeping the hose end higher than the reservoir, reposition the reservoir forward and down out of the way. 7. Using a clean, lint-free shop cloth, wipe any dirt away from the steering pump supply hose/tube connection area on the hydro-boost (this is the center hose/tube of the three). 8. Disconnect the power steering supply hose/tube from the hydro-boost unit and wrap a clean lint-free shop cloth around the end of the hose and secure it in the engine compartment. 9. Using a clean lint-free shop cloth, clean any dirt off of the inlet port adapter valve assembly. Before installing the inlet port adapter, place a shop Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9293 cloth below the booster supply port in order to capture any fluid exiting the hydro-boost unit. 10. Install the inlet port adapter, CH 47950-2 (2) into the booster supply port. 11. Using a torque wrench, slowly tighten the inlet port adapter to 16 N.m (12 lb-ft). If the clear tube was removed from the inlet port adapter assembly, be sure it is reinstalled. 12. Before each use of the accumulator pressure clamp, CH 47950-1, be sure to grease the clamp bolt and anti rotation washer with wheel bearing grease. 13. Install the accumulator pressure clamp, CH 47950-1 (1), by sliding it over the accumulator and straddling the hydro-boost housing. 14. Confirm that the accumulator pressure clamp is squarely seated onto the booster housing and accumulator, and place the 3/4 inch containment bolt into the fixture. Install the nut hand-tight onto the containment bolt. 15. Check and make sure that the fixture washer is correctly positioned between the end of the accumulator, and that the pin is engaged in the end of the bolt. The tab on the washer should be rotated clockwise so it is located below the master cylinder mounting flange ear. Caution: Incorrect installation of the washer will result in damage to the accumulator end. 16. Hand-tighten the accumulator pressure clamp bolt. Make sure the clamp is level and the tube is square to the end of the accumulator. 17. Place a shop cloth next to the opening of the inlet port adapter in order to capture any fluid exiting the hydro-boost unit. Important: Do not exceed 65 N.m (48 lb-ft) torque. Important: A torque wrench must be used to tighten the fixture clamp bolt 18. Slowly tighten the fixture clamp bolt while monitoring the inlet port adapter tube for signs of power steering fluid. Stop tightening of the bolt when either fluid is observed (below the maximum 65 N.m (48 lb-ft) torque) OR The 65 N.m (48 lb-ft) maximum bolt torque is achieved (with no fluid Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9294 visible in the clear adapter tube). If fluid is seen coming out of the inlet port adapter up to 65 Nm (48 lb-ft) maximum torque, the hydro-boost booster assembly is "OK", Proceed to Step 19. A. If NO fluid is seen exiting from the inlet port adapter, complete Steps 19-27 and then repeat Steps 1-18. B. If no fluid is visible from the second evaluation, replace the hydro-boost unit. Proceed to the appropriate procedure found in this bulletin. 19. Loosen the clamp bolt, remove the clamp containment bolt, and remove the accumulator pressure clamp. Remove the inlet port adapter from the supply port of the booster. Wipe the excess power steering fluid off of the adapter with a clean, lint-free shop cloth. Store the adapter in a clean location, such as a plastic bag. 20. Reinstall the supply hose/tube to the booster. Tighten Tighten to 28 N.m (21 lb-ft). 21. Clean any spilled fluid from the outside of the booster. 22. For Express/Savana only: ^ Connect the reservoir outlet hose to the booster unit. Keeping the hose end higher than reservoir, reposition the reservoir onto the mounting studs. A. Install the remote power steering reservoir mounting nuts. Tighten Tighten to 7 Nm (58 lb in). 23. Start the engine and run at idle. Depress the brake pedal 5 times. Turn the steering wheel to the "steering lock" position. Hold for 1-2 seconds. Check to see if there is any leakage from the ports/fittings. 24. Turn the engine off. 25. If leaks were observed, re-check that the fittings are at the recommended torque values. Repeat Steps 17 and 18. 26. Check the power steering reservoir fluid level, add fluid if necessary. 27. Close the hood. Hydro-Boost(R) Replacement - Avalanche, Express, Savana, Silverado, Sierra, Suburban, Yukon XL Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Apply the park brake and block the wheels. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9295 2. Remove the master cylinder from the booster. Do not remove the pipes from the master cylinder. Set the master cylinder aside in the engine compartment. 3. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 4. Disconnect the electrical connector from the stop lamp switch. 5. Remove the retainer from the brake pedal pin. 6. Remove the stop lamp switch and the pushrod to the power brake booster from the brake pedal pin. 7. Unsnap the stop lamp switch from the power brake booster pushrod. 8. Remove the 4 booster to bulkhead nuts. 9. Remove the booster assembly. 10. Remove the gasket. Installation Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9296 1. Install the gasket. 2. Install the booster assembly. 3. Install the 4 booster to bulkhead nuts. Tighten Tighten the nuts to 36 N.m (26 lb-ft). 4. Snap the stop lamp switch onto the pushrod to the power brake booster. 5. Install the stop lamp switch with the pushrod on the brake pedal pin. 6. Install the brake switch retainer. 7. Connect the electrical connector to the stop lamp switch. 8. Install the master cylinder to the booster. 9. Install the master cylinder mounting nuts. Tighten Tighten the nuts to 36 N.m (27 lb-ft). 10. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9297 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kPa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove J 43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Hydro-Boost(R) Replacement -- Kodiak, TopKick Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Block the wheels. 2. Disconnect the electrical connectors from the electrohydraulic pump and the flow switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9298 3. Remove the master cylinder nuts. Do not remove the pipes from the master cylinder. Position the master cylinder away from the booster head. Secure the master cylinder in an upright position. 4. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 5. Remove the booster pump rod retainer from the lever. 6. Remove the stop lamp switch from the lever. 7. Remove the booster pump rod from the lever. 8. Remove the nuts at the booster. 9. Remove the booster assembly. Installation 1. Install the booster assembly to the vehicle. 2. Install the nuts at the booster. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9299 Tighten Tighten the nuts to 50 N.m (37 lb-ft). 3. Install the booster pump rod to the lever. 4. Install the stop lamp switch to the lever. 5. Install the booster pump rod retainer. 6. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). 7. Install the master cylinder. 8. Install the mounting nuts. Tighten Tighten the mounting bolts to 50 Nm (37 lb-ft). 9. Install the electrical connectors to the electrohydraulic pump and the flow switch. 10. Fill the hydraulic pump reservoir. Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9300 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kpa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove 1 J43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9301 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9302 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9303 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > NHTSA05V043000 > Feb > 05 > Recall 05V043000: Brake Hydro-Boost Unit Defect Hydraulic Brake Booster: Recalls Recall 05V043000: Brake Hydro-Boost Unit Defect MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Avalanche 2004-2005 Chevrolet/Express 2004-2005 Chevrolet/Kodiak 2004-2005 Chevrolet/Silverado 2004-2005 Chevrolet/Suburban 2004-2005 GMC/Savana 2004-2005 GMC/Sierra 2004-2005 GMC/Topkick 2004-2005 GMC/Yukon XL 2004-2005 Hummer/H2 2004-2005 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID Number: 05V043000 RECALL DATE: Feb 04, 2005 COMPONENT: Service Brakes, Hydraulic POTENTIAL NUMBER OF UNITS AFFECTED: 155465 SUMMARY: Certain trucks, sport utility vehicles, and vans equipped with Bosch Hydro-Boost brake assemblies, the hydraulic brake booster pressure accumulator may crack and separate from the hydro-boost assembly during normal operating conditions. CONSEQUENCE: If a separation occurred and the hood of the vehicle were open, fragments from the accumulator could cause injury to people in the immediate area. The presence of this crack or fractured surface could allow the hydraulic fluid to leak from the accumulator circuit of the booster assembly. The loss of fluid would cause increased steering and braking effort and a crash may occur without prior warning. REMEDY: Dealers will test the Hydro-Boost assembly for functional operation of the two-function valve. If the Hydro-Boost assembly fails the test, dealers are to replace the assembly. The recall is expected to begin during March 2005. Owners should contact Chevrolet at 1-800-630-2438, GMC Trucks at 1-866-996-9463 and Hummer at 1-800-732-5493. NOTES: GM recall No. 05006. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 04004 > Jun > 04 > Recall - Brake Hydroboost Relief Valve Seal Defect Technical Service Bulletin # 04004 Date: 040601 Recall - Brake Hydroboost Relief Valve Seal Defect File In Section: Product Recalls Bulletin No.: 04004 Date: June 2004 F/CMVSS NONCOMPLIANCE RECALL SUBJECT: BRAKE HYDRO-BOOST RELIEF VALVE SEAL FRACTURE MODELS: 2003-2004 CADILLAC ESCALADE, ESCALADE EXT, ESCALADE ESV 2003-2004 CHEVROLET SILVERADO, AVALANCHE, SUBURBAN, EXPRESS 2004 CHEVROLET TAHOE 2003-2004 GMC SIERRA, YUKON, YUKON XL, SAVANA CONDITION General Motors has decided that certain 2003 and 2004 model year Cadillac Escalade, Escalade EXT and Escalade ESV; Chevrolet Silverado, Avalanche, Suburban, and Express; GMC Sierra, Yukon, Yukon XL, and Savana; and 2004 model year Chevrolet Tahoe vehicles fail to conform to either Federal/Canada Motor Vehicle Safety Standard 105, "Hydraulic and Electric Brake System", or Standard 135, "Light Vehicle Brake Systems". These vehicles may have a relief valve bore within the brake hydro-boost module that is not to specification. An out-of-specification bore could result in fracture of the relief valve 0-ring seal within the module. If this happens, during braking applications the driver may be able to hear an engine compartment noise similar to the sound that occurs when the steering wheel is turned to a full stop position. The driver could also experience a slight increase in steering efforts while braking and parking. Under certain driving conditions, a fractured seal may require a slight increase in the applied brake pedal effort to achieve the same vehicle deceleration rate as prior to the seal fracture. If this were to occur, it could result in a vehicle crash without prior warning. CORRECTION Dealers are to inspect the hydro-boost module, and replace the relief valve, if necessary. VEHICLES INVOLVED Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 04004 > Jun > 04 > Recall - Brake Hydroboost Relief Valve Seal Defect > Page 9312 Involved are certain 2003 and 2004 model year Cadillac Escalade, Escalade EXT and Escalade ESV; Chevrolet Silverado, Avalanche, Suburban, and Express; GMC Sierra, Yukon, Yukon XL, and Savana; and 2004 model year Chevrolet Tahoe vehicles built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For U.S.: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. For Canada & IPC: Computer listings containing the complete Vehicle Identification Number, customer name and address data of involved vehicles have Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 04004 > Jun > 04 > Recall - Brake Hydroboost Relief Valve Seal Defect > Page 9313 been prepared, and are being furnished to involved dealers. The customer name and address data will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Important It is estimated that only 20% of involved vehicles will require Valve Kit Repair. Please order parts accordingly. COURTESY TRANSPORTATION The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 04004 > Jun > 04 > Recall - Brake Hydroboost Relief Valve Seal Defect > Page 9314 CLAIM INFORMATION CUSTOMER NOTIFICATION - For US and CANADA General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. This bulletin is notice to you that the new motor vehicles included in this recall may not comply with the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles without first performing the recall correction, your dealership may be subject to a civil penalty for each such sale. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for inspecting, and if necessary, replacing the hydraulic brake booster relief valve. 1. Open the hood. Important You may notice that there is a blue epoxy-type material in the center of the relief valve described in the next step. This material will be found in both the original arid replacement relief valves. 2. Locate the relief valve (2) on the hydraulic brake booster. The valve is located in the front of the brake booster directly behind the master cylinder reservoir (1). ^ If the color of the relief valve is metallic yellow or has a brass appearance, then further action is required. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 04004 > Jun > 04 > Recall - Brake Hydroboost Relief Valve Seal Defect > Page 9315 ^ If the color of the relief valve is silver or aluminum, continue to the next step. Important If present, the stamped number being described in the next step would be on the mounting surface for the master cylinder on the hydraulic brake booster. The number may be difficult to see if there is any corrosion on the unpainted surface. As a result, it may be necessary to clean the surface with a piece of emery or sandpaper. 3. Inspect the hydraulic brake booster at the location shown (4) for a stamped number. The location (4) is the same surface that the master cylinder mounts on, just above the outboard mounting bolt and nut (5). Also inspect for a paint mark (3) near the master cylinder outboard mounting bolt (5). If a stamped number is found it will be a 1, 2, 3, or 4. If a paint mark is found, it will be yellow, pink, or white. ^ If a yellow, pink, or white paint mark IS visible, no further inspection or repairs are required. Disregard any stamped number found when a yellow, pink, or white paint mark is visible. ^ If there are NO paint marks and there IS a stamped number 2, 3, or 4 visible, no further inspection or repairs are required. ^ If there are NO paint marks and there IS a stamped number 1 visible, then proceed to the next step. ^ If there are NO paint marks and there are NO stamped numbers visible, then proceed to the next step. Caution Care should be taken when working around the accumulator since it contains high-pressure compressed gas and hydraulic fluid. 4. With the ignition in the OFF position, pump the brake pedal a minimum of ten times. 5. On van models, remove the two bolts that attach the diagonal brace between the left front fender and radiator support. Remove the brace and the water deflector that is attached to it. 6. On all models, remove the two nuts that attach the master cylinder to the hydraulic brake booster. A 13 mm wrench installed on the bolt head may be required to prevent the bolt from spinning. Important On full size pickups and utilities, the bracket that attaches the brake combination valve will need to be removed from the mounting bolts at the same time that the master cylinder is removed and repositioned in the next step. Notice When repositioning the master cylinder in the next step, use care not to pinch, kink, or damage the brake hoses or pipes. 7. Remove and reposition the master cylinder away from the hydraulic brake booster so that the machined surface on the front of the booster where the master cylinder was mounted is visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 04004 > Jun > 04 > Recall - Brake Hydroboost Relief Valve Seal Defect > Page 9316 8. Inspect the machined surface that was covered by the master cylinder on the front of the hydraulic brake booster at the location (1) shown for a stamped number. The stamped number will be a number 1, 2, 3, or 4. ^ If a stamped number 1 is visible, then the relief valve must be replaced. Proceed to the next step. ^ If a stamped number 2, 3, or 4 is visible, then no further action is required. Proceed to Step 14 and reinstall the master cylinder. ^ If no stamped number is visible, then no further action is required. Proceed to Step 14 and reinstall the master cylinder. 9. Cover the master cylinder with a clean shop towel in order to protect it from fluids or cleaners. Also, place a shop towel under the hydraulic brake booster to absorb any fluid that may leak out of the unit when the relief valve is removed in the next step. 10. Using the tool (2) included with the new relief valve, unscrew the original relief valve (1) from the hydraulic brake booster. Notice DO NOT blow compressed air into the bore or use any commercially available cleaners to flush the valve bore in the next step. This could damage the booster or master cylinder. 11. Inspect the two 0-rings on the original valve for signs of damage. If an 0-ring is missing, broken, or damaged, inspect the bore in the hydraulic brake booster for any pieces or debris using a non-metallic type tool or a clean "lint-free" towel. Important A torque wrench must be used when tightening the valve in the next step. In addition, a 3/8 inch drive to 1/4 inch drive adapter will be needed if your torque wrench is a 3/8 inch drive. Important After tightening the NEW relief valve in the next step, a small gap may exist between the head on the valve and the hydraulic brake booster. This condition is normal. 12. Insert the NEW relief valve into the bore. Tighten Tighten to 17 Nm (13 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 04004 > Jun > 04 > Recall - Brake Hydroboost Relief Valve Seal Defect > Page 9317 13. Using a clean shop towel, clean up any fluid that may have leaked out of the hydraulic brake booster when removing the original valve. 14. Position the master cylinder (and brake combination valve mounting bracket on full size pickups and utilities) on the mounting bolts on the hydraulic brake booster. 15. With the master cylinder mounted flush to the booster, install the nuts. Tighten Tighten the nuts to 33 N.m (24 lb ft). 16. On van models, install the diagonal brace with the water deflector attached to it between the left fender and the radiator. Install the two bolts. Tighten Tighten bolts to 25 N.m (18 lb ft). 17. Start the engine and verify the hydraulic brake booster operation. 18. Turn the engine OFF and check the power steering fluid reservoir. Add fluid if necessary. 19. Close the hood. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 04004 > Jun > 04 > Recall - Brake Hydroboost Relief Valve Seal Defect > Page 9318 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > 04004 > Jun > 04 > Recall - Brake Hydroboost Relief Valve Seal Defect > Page 9319 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Recalls for Hydraulic Brake Booster: > NHTSA04V045000 > Feb > 04 > Recall 04V045000: Possible Hydro-Boost Defect Hydraulic Brake Booster: Recalls Recall 04V045000: Possible Hydro-Boost Defect DEFECT: Certain sport utility vehicles, pickup trucks, and passenger vans fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 135, "Passenger Car Brake Systems." Some of these vehicles were produced with an out-of-specification brake hydro-boost housing relief valve bore. Consequently, the valve O-ring seal may fracture. Steering efforts may be slightly increased while braking or parking. Under certain driving conditions, a fractured seal may also require an increase in the applied brake pedal effort to achieve the same vehicle deceleration. REMEDY: Dealers are to replace the hydro-boost relief valve. The manufacturer has reported that owner notification is expected to begin during the second quarter of 2004. Owners may contact Cadillac at 1-866-982-2339; Chevrolet at 1-800-630-2438; GMC at 1-866-996-9463; or Hummer at 1-866-486-6376. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking Technical Service Bulletin # 05006 Date: 050323 Recall - Brake Booster Pressure Accumulator Cracking Product Safety - Hydro-Boost Accumulator Over-Pressurization # 05006 - (Mar 23, 2005) Models: 2004 Chevrolet Kodiak 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban 2004 GMC TopKick 2004-2005 GMC Savana, Sierra, Yukon XL Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Yukon XL vehicles. On some of these vehicles, the hydraulic brake booster's pressure accumulator may crack and/or separate from the Hydro-Boost(R) assembly during normal vehicle operating conditions. If a separation were to occur and the hood of the vehicle were open, fragments from the accumulator could cause injury to people in the immediate area. In addition, the presence of this crack or fractured surface could allow the hydraulic fluid to leak from the accumulator circuit of the booster assembly. The loss of fluid would cause increased steering and braking effort. Correction Dealers are to inspect the hydraulic brake booster, and replace it if necessary. Vehicles Involved Involved are certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9329 Yukon XL vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information A very small number of vehicles (less than 90 world-wide) will require the replacement of the hydraulic brake booster. Do not order boosters for shelf stock. When a replacement is required, order the appropriate booster from GMSPO. All replaced boosters (excluding Export) must be returned to the Warranty Parts Center. Hold the booster until you receive the request for return. Special Tool Beginning February 18, 2005, each dealer was shipped a Hydro-Boost Checking Tool, CH 47950, for use in this recall. This tool is being furnished at no charge. Additional tools, if required, may be purchased by contacting SPX Kent-Moore at 1-800-468-6657. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9330 Claim Information Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification -- For Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- For US and Export (US States, Territories and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9331 of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Inspection Tools Required CH 47950 Hydro-Boost Checking Tool 1. With the vehicle transmission in PARK or NEUTRAL, set the park brake. 2. With the engine OFF, make a minimum of five (5) high effort brake applies until the pedal feels hard. 3. Start the engine. Important: DO NOT depress the brake pedal until instructed. 4. Turn the steering wheel to the "steering lock" (fully turned) position. Hold at the steering lock position for 1 to 2 seconds and then release the steering wheel. Repeat a total of 3 times. 5. Turn the vehicle off being careful not to step on the brake pedal. 6. For Express/Savana only: A. Remove the remote power steering reservoir mounting nuts. B. Disconnect the reservoir outlet hose from the booster unit. Keeping the hose end higher than the reservoir, reposition the reservoir forward and down out of the way. 7. Using a clean, lint-free shop cloth, wipe any dirt away from the steering pump supply hose/tube connection area on the hydro-boost (this is the center hose/tube of the three). 8. Disconnect the power steering supply hose/tube from the hydro-boost unit and wrap a clean lint-free shop cloth around the end of the hose and secure it in the engine compartment. 9. Using a clean lint-free shop cloth, clean any dirt off of the inlet port adapter valve assembly. Before installing the inlet port adapter, place a shop Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9332 cloth below the booster supply port in order to capture any fluid exiting the hydro-boost unit. 10. Install the inlet port adapter, CH 47950-2 (2) into the booster supply port. 11. Using a torque wrench, slowly tighten the inlet port adapter to 16 N.m (12 lb-ft). If the clear tube was removed from the inlet port adapter assembly, be sure it is reinstalled. 12. Before each use of the accumulator pressure clamp, CH 47950-1, be sure to grease the clamp bolt and anti rotation washer with wheel bearing grease. 13. Install the accumulator pressure clamp, CH 47950-1 (1), by sliding it over the accumulator and straddling the hydro-boost housing. 14. Confirm that the accumulator pressure clamp is squarely seated onto the booster housing and accumulator, and place the 3/4 inch containment bolt into the fixture. Install the nut hand-tight onto the containment bolt. 15. Check and make sure that the fixture washer is correctly positioned between the end of the accumulator, and that the pin is engaged in the end of the bolt. The tab on the washer should be rotated clockwise so it is located below the master cylinder mounting flange ear. Caution: Incorrect installation of the washer will result in damage to the accumulator end. 16. Hand-tighten the accumulator pressure clamp bolt. Make sure the clamp is level and the tube is square to the end of the accumulator. 17. Place a shop cloth next to the opening of the inlet port adapter in order to capture any fluid exiting the hydro-boost unit. Important: Do not exceed 65 N.m (48 lb-ft) torque. Important: A torque wrench must be used to tighten the fixture clamp bolt 18. Slowly tighten the fixture clamp bolt while monitoring the inlet port adapter tube for signs of power steering fluid. Stop tightening of the bolt when either fluid is observed (below the maximum 65 N.m (48 lb-ft) torque) OR The 65 N.m (48 lb-ft) maximum bolt torque is achieved (with no fluid Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9333 visible in the clear adapter tube). If fluid is seen coming out of the inlet port adapter up to 65 Nm (48 lb-ft) maximum torque, the hydro-boost booster assembly is "OK", Proceed to Step 19. A. If NO fluid is seen exiting from the inlet port adapter, complete Steps 19-27 and then repeat Steps 1-18. B. If no fluid is visible from the second evaluation, replace the hydro-boost unit. Proceed to the appropriate procedure found in this bulletin. 19. Loosen the clamp bolt, remove the clamp containment bolt, and remove the accumulator pressure clamp. Remove the inlet port adapter from the supply port of the booster. Wipe the excess power steering fluid off of the adapter with a clean, lint-free shop cloth. Store the adapter in a clean location, such as a plastic bag. 20. Reinstall the supply hose/tube to the booster. Tighten Tighten to 28 N.m (21 lb-ft). 21. Clean any spilled fluid from the outside of the booster. 22. For Express/Savana only: ^ Connect the reservoir outlet hose to the booster unit. Keeping the hose end higher than reservoir, reposition the reservoir onto the mounting studs. A. Install the remote power steering reservoir mounting nuts. Tighten Tighten to 7 Nm (58 lb in). 23. Start the engine and run at idle. Depress the brake pedal 5 times. Turn the steering wheel to the "steering lock" position. Hold for 1-2 seconds. Check to see if there is any leakage from the ports/fittings. 24. Turn the engine off. 25. If leaks were observed, re-check that the fittings are at the recommended torque values. Repeat Steps 17 and 18. 26. Check the power steering reservoir fluid level, add fluid if necessary. 27. Close the hood. Hydro-Boost(R) Replacement - Avalanche, Express, Savana, Silverado, Sierra, Suburban, Yukon XL Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Apply the park brake and block the wheels. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9334 2. Remove the master cylinder from the booster. Do not remove the pipes from the master cylinder. Set the master cylinder aside in the engine compartment. 3. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 4. Disconnect the electrical connector from the stop lamp switch. 5. Remove the retainer from the brake pedal pin. 6. Remove the stop lamp switch and the pushrod to the power brake booster from the brake pedal pin. 7. Unsnap the stop lamp switch from the power brake booster pushrod. 8. Remove the 4 booster to bulkhead nuts. 9. Remove the booster assembly. 10. Remove the gasket. Installation Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9335 1. Install the gasket. 2. Install the booster assembly. 3. Install the 4 booster to bulkhead nuts. Tighten Tighten the nuts to 36 N.m (26 lb-ft). 4. Snap the stop lamp switch onto the pushrod to the power brake booster. 5. Install the stop lamp switch with the pushrod on the brake pedal pin. 6. Install the brake switch retainer. 7. Connect the electrical connector to the stop lamp switch. 8. Install the master cylinder to the booster. 9. Install the master cylinder mounting nuts. Tighten Tighten the nuts to 36 N.m (27 lb-ft). 10. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9336 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kPa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove J 43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Hydro-Boost(R) Replacement -- Kodiak, TopKick Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Block the wheels. 2. Disconnect the electrical connectors from the electrohydraulic pump and the flow switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9337 3. Remove the master cylinder nuts. Do not remove the pipes from the master cylinder. Position the master cylinder away from the booster head. Secure the master cylinder in an upright position. 4. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 5. Remove the booster pump rod retainer from the lever. 6. Remove the stop lamp switch from the lever. 7. Remove the booster pump rod from the lever. 8. Remove the nuts at the booster. 9. Remove the booster assembly. Installation 1. Install the booster assembly to the vehicle. 2. Install the nuts at the booster. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9338 Tighten Tighten the nuts to 50 N.m (37 lb-ft). 3. Install the booster pump rod to the lever. 4. Install the stop lamp switch to the lever. 5. Install the booster pump rod retainer. 6. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). 7. Install the master cylinder. 8. Install the mounting nuts. Tighten Tighten the mounting bolts to 50 Nm (37 lb-ft). 9. Install the electrical connectors to the electrohydraulic pump and the flow switch. 10. Fill the hydraulic pump reservoir. Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9339 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kpa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove 1 J43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9340 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9341 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9342 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > NHTSA05V043000 > Feb > 05 > Recall 05V043000: Brake Hydro-Boost Unit Defect Hydraulic Brake Booster: All Technical Service Bulletins Recall 05V043000: Brake Hydro-Boost Unit Defect MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Avalanche 2004-2005 Chevrolet/Express 2004-2005 Chevrolet/Kodiak 2004-2005 Chevrolet/Silverado 2004-2005 Chevrolet/Suburban 2004-2005 GMC/Savana 2004-2005 GMC/Sierra 2004-2005 GMC/Topkick 2004-2005 GMC/Yukon XL 2004-2005 Hummer/H2 2004-2005 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID Number: 05V043000 RECALL DATE: Feb 04, 2005 COMPONENT: Service Brakes, Hydraulic POTENTIAL NUMBER OF UNITS AFFECTED: 155465 SUMMARY: Certain trucks, sport utility vehicles, and vans equipped with Bosch Hydro-Boost brake assemblies, the hydraulic brake booster pressure accumulator may crack and separate from the hydro-boost assembly during normal operating conditions. CONSEQUENCE: If a separation occurred and the hood of the vehicle were open, fragments from the accumulator could cause injury to people in the immediate area. The presence of this crack or fractured surface could allow the hydraulic fluid to leak from the accumulator circuit of the booster assembly. The loss of fluid would cause increased steering and braking effort and a crash may occur without prior warning. REMEDY: Dealers will test the Hydro-Boost assembly for functional operation of the two-function valve. If the Hydro-Boost assembly fails the test, dealers are to replace the assembly. The recall is expected to begin during March 2005. Owners should contact Chevrolet at 1-800-630-2438, GMC Trucks at 1-866-996-9463 and Hummer at 1-800-732-5493. NOTES: GM recall No. 05006. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 04004 > Jun > 04 > Recall - Brake Hydroboost Relief Valve Seal Defect Technical Service Bulletin # 04004 Date: 040601 Recall - Brake Hydroboost Relief Valve Seal Defect File In Section: Product Recalls Bulletin No.: 04004 Date: June 2004 F/CMVSS NONCOMPLIANCE RECALL SUBJECT: BRAKE HYDRO-BOOST RELIEF VALVE SEAL FRACTURE MODELS: 2003-2004 CADILLAC ESCALADE, ESCALADE EXT, ESCALADE ESV 2003-2004 CHEVROLET SILVERADO, AVALANCHE, SUBURBAN, EXPRESS 2004 CHEVROLET TAHOE 2003-2004 GMC SIERRA, YUKON, YUKON XL, SAVANA CONDITION General Motors has decided that certain 2003 and 2004 model year Cadillac Escalade, Escalade EXT and Escalade ESV; Chevrolet Silverado, Avalanche, Suburban, and Express; GMC Sierra, Yukon, Yukon XL, and Savana; and 2004 model year Chevrolet Tahoe vehicles fail to conform to either Federal/Canada Motor Vehicle Safety Standard 105, "Hydraulic and Electric Brake System", or Standard 135, "Light Vehicle Brake Systems". These vehicles may have a relief valve bore within the brake hydro-boost module that is not to specification. An out-of-specification bore could result in fracture of the relief valve 0-ring seal within the module. If this happens, during braking applications the driver may be able to hear an engine compartment noise similar to the sound that occurs when the steering wheel is turned to a full stop position. The driver could also experience a slight increase in steering efforts while braking and parking. Under certain driving conditions, a fractured seal may require a slight increase in the applied brake pedal effort to achieve the same vehicle deceleration rate as prior to the seal fracture. If this were to occur, it could result in a vehicle crash without prior warning. CORRECTION Dealers are to inspect the hydro-boost module, and replace the relief valve, if necessary. VEHICLES INVOLVED Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 04004 > Jun > 04 > Recall - Brake Hydroboost Relief Valve Seal Defect > Page 9351 Involved are certain 2003 and 2004 model year Cadillac Escalade, Escalade EXT and Escalade ESV; Chevrolet Silverado, Avalanche, Suburban, and Express; GMC Sierra, Yukon, Yukon XL, and Savana; and 2004 model year Chevrolet Tahoe vehicles built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For U.S.: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. For Canada & IPC: Computer listings containing the complete Vehicle Identification Number, customer name and address data of involved vehicles have Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 04004 > Jun > 04 > Recall - Brake Hydroboost Relief Valve Seal Defect > Page 9352 been prepared, and are being furnished to involved dealers. The customer name and address data will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned. These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall. PARTS INFORMATION Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Important It is estimated that only 20% of involved vehicles will require Valve Kit Repair. Please order parts accordingly. COURTESY TRANSPORTATION The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 04004 > Jun > 04 > Recall - Brake Hydroboost Relief Valve Seal Defect > Page 9353 CLAIM INFORMATION CUSTOMER NOTIFICATION - For US and CANADA General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. This bulletin is notice to you that the new motor vehicles included in this recall may not comply with the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles without first performing the recall correction, your dealership may be subject to a civil penalty for each such sale. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for inspecting, and if necessary, replacing the hydraulic brake booster relief valve. 1. Open the hood. Important You may notice that there is a blue epoxy-type material in the center of the relief valve described in the next step. This material will be found in both the original arid replacement relief valves. 2. Locate the relief valve (2) on the hydraulic brake booster. The valve is located in the front of the brake booster directly behind the master cylinder reservoir (1). ^ If the color of the relief valve is metallic yellow or has a brass appearance, then further action is required. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 04004 > Jun > 04 > Recall - Brake Hydroboost Relief Valve Seal Defect > Page 9354 ^ If the color of the relief valve is silver or aluminum, continue to the next step. Important If present, the stamped number being described in the next step would be on the mounting surface for the master cylinder on the hydraulic brake booster. The number may be difficult to see if there is any corrosion on the unpainted surface. As a result, it may be necessary to clean the surface with a piece of emery or sandpaper. 3. Inspect the hydraulic brake booster at the location shown (4) for a stamped number. The location (4) is the same surface that the master cylinder mounts on, just above the outboard mounting bolt and nut (5). Also inspect for a paint mark (3) near the master cylinder outboard mounting bolt (5). If a stamped number is found it will be a 1, 2, 3, or 4. If a paint mark is found, it will be yellow, pink, or white. ^ If a yellow, pink, or white paint mark IS visible, no further inspection or repairs are required. Disregard any stamped number found when a yellow, pink, or white paint mark is visible. ^ If there are NO paint marks and there IS a stamped number 2, 3, or 4 visible, no further inspection or repairs are required. ^ If there are NO paint marks and there IS a stamped number 1 visible, then proceed to the next step. ^ If there are NO paint marks and there are NO stamped numbers visible, then proceed to the next step. Caution Care should be taken when working around the accumulator since it contains high-pressure compressed gas and hydraulic fluid. 4. With the ignition in the OFF position, pump the brake pedal a minimum of ten times. 5. On van models, remove the two bolts that attach the diagonal brace between the left front fender and radiator support. Remove the brace and the water deflector that is attached to it. 6. On all models, remove the two nuts that attach the master cylinder to the hydraulic brake booster. A 13 mm wrench installed on the bolt head may be required to prevent the bolt from spinning. Important On full size pickups and utilities, the bracket that attaches the brake combination valve will need to be removed from the mounting bolts at the same time that the master cylinder is removed and repositioned in the next step. Notice When repositioning the master cylinder in the next step, use care not to pinch, kink, or damage the brake hoses or pipes. 7. Remove and reposition the master cylinder away from the hydraulic brake booster so that the machined surface on the front of the booster where the master cylinder was mounted is visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 04004 > Jun > 04 > Recall - Brake Hydroboost Relief Valve Seal Defect > Page 9355 8. Inspect the machined surface that was covered by the master cylinder on the front of the hydraulic brake booster at the location (1) shown for a stamped number. The stamped number will be a number 1, 2, 3, or 4. ^ If a stamped number 1 is visible, then the relief valve must be replaced. Proceed to the next step. ^ If a stamped number 2, 3, or 4 is visible, then no further action is required. Proceed to Step 14 and reinstall the master cylinder. ^ If no stamped number is visible, then no further action is required. Proceed to Step 14 and reinstall the master cylinder. 9. Cover the master cylinder with a clean shop towel in order to protect it from fluids or cleaners. Also, place a shop towel under the hydraulic brake booster to absorb any fluid that may leak out of the unit when the relief valve is removed in the next step. 10. Using the tool (2) included with the new relief valve, unscrew the original relief valve (1) from the hydraulic brake booster. Notice DO NOT blow compressed air into the bore or use any commercially available cleaners to flush the valve bore in the next step. This could damage the booster or master cylinder. 11. Inspect the two 0-rings on the original valve for signs of damage. If an 0-ring is missing, broken, or damaged, inspect the bore in the hydraulic brake booster for any pieces or debris using a non-metallic type tool or a clean "lint-free" towel. Important A torque wrench must be used when tightening the valve in the next step. In addition, a 3/8 inch drive to 1/4 inch drive adapter will be needed if your torque wrench is a 3/8 inch drive. Important After tightening the NEW relief valve in the next step, a small gap may exist between the head on the valve and the hydraulic brake booster. This condition is normal. 12. Insert the NEW relief valve into the bore. Tighten Tighten to 17 Nm (13 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 04004 > Jun > 04 > Recall - Brake Hydroboost Relief Valve Seal Defect > Page 9356 13. Using a clean shop towel, clean up any fluid that may have leaked out of the hydraulic brake booster when removing the original valve. 14. Position the master cylinder (and brake combination valve mounting bracket on full size pickups and utilities) on the mounting bolts on the hydraulic brake booster. 15. With the master cylinder mounted flush to the booster, install the nuts. Tighten Tighten the nuts to 33 N.m (24 lb ft). 16. On van models, install the diagonal brace with the water deflector attached to it between the left fender and the radiator. Install the two bolts. Tighten Tighten bolts to 25 N.m (18 lb ft). 17. Start the engine and verify the hydraulic brake booster operation. 18. Turn the engine OFF and check the power steering fluid reservoir. Add fluid if necessary. 19. Close the hood. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 04004 > Jun > 04 > Recall - Brake Hydroboost Relief Valve Seal Defect > Page 9357 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > 04004 > Jun > 04 > Recall - Brake Hydroboost Relief Valve Seal Defect > Page 9358 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Brake Booster: > NHTSA04V045000 > Feb > 04 > Recall 04V045000: Possible Hydro-Boost Defect Hydraulic Brake Booster: All Technical Service Bulletins Recall 04V045000: Possible Hydro-Boost Defect DEFECT: Certain sport utility vehicles, pickup trucks, and passenger vans fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 135, "Passenger Car Brake Systems." Some of these vehicles were produced with an out-of-specification brake hydro-boost housing relief valve bore. Consequently, the valve O-ring seal may fracture. Steering efforts may be slightly increased while braking or parking. Under certain driving conditions, a fractured seal may also require an increase in the applied brake pedal effort to achieve the same vehicle deceleration. REMEDY: Dealers are to replace the hydro-boost relief valve. The manufacturer has reported that owner notification is expected to begin during the second quarter of 2004. Owners may contact Cadillac at 1-866-982-2339; Chevrolet at 1-800-630-2438; GMC at 1-866-996-9463; or Hummer at 1-866-486-6376. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Page 9363 Hydraulic Brake Booster: Service and Repair Hydraulic Brake Booster Replacement Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: Hydraulic brake systems use two distinct and incompatible fluids. Power steering fluid is used in the hydraulic brake booster system. Brake fluid is used in the master cylinder and brake pipes. Use extreme care when selecting brake system fluids, or seal damage can result. Refer to General Information to select the correct fluid. Checking and Adding Fluid For information on checking and adding fluid to the hydraulic booster system, refer to Checking and Adding Power Steering Fluid (Without Hydroboost) Checking and Adding Power Steering Fluid (With Hydroboost) in Power Steering System. Bleeding the Hydraulic Booster System Refer to Bleeding the Power Steering System in Power Steering System. Flushing the Hydraulic Booster System Refer to Flushing the Power Steering System in Power Steering System. Removal Procedure 1. Apply the park brake and block the wheels. 2. Disconnect the inlet hose, the steering gear, and the return hoses from the booster assembly. 3. Remove the master cylinder. 4. Remove the stop lamp switch. Refer to Stop Lamp Switch Replacement in Lighting Systems. 5. Remove the 4 booster to bulkhead nuts. 6. Remove the booster assembly. 7. Remove the gasket. Installation Procedure 1. Install the gasket. 2. Install the booster assembly. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the 4 booster to bulkhead nuts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Technical Service Bulletins > Page 9364 ^ Tighten the nuts to 33 Nm (24 ft. lbs.). 4. Install the stop lamp switch. Refer to Stop Lamp Switch Replacement in Lighting Systems. 5. Install the master cylinder. 6. Connect the return hose, the steering gear, and the inlet hoses. 7. Bleed the hydraulic booster system. Refer to Bleeding the Power Steering System in Power Steering System. 8. Release the park brake and unblock the wheels. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking Technical Service Bulletin # 05006 Date: 050323 Recall - Brake Booster Pressure Accumulator Cracking Product Safety - Hydro-Boost Accumulator Over-Pressurization # 05006 - (Mar 23, 2005) Models: 2004 Chevrolet Kodiak 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban 2004 GMC TopKick 2004-2005 GMC Savana, Sierra, Yukon XL Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Yukon XL vehicles. On some of these vehicles, the hydraulic brake booster's pressure accumulator may crack and/or separate from the Hydro-Boost(R) assembly during normal vehicle operating conditions. If a separation were to occur and the hood of the vehicle were open, fragments from the accumulator could cause injury to people in the immediate area. In addition, the presence of this crack or fractured surface could allow the hydraulic fluid to leak from the accumulator circuit of the booster assembly. The loss of fluid would cause increased steering and braking effort. Correction Dealers are to inspect the hydraulic brake booster, and replace it if necessary. Vehicles Involved Involved are certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9373 Yukon XL vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information A very small number of vehicles (less than 90 world-wide) will require the replacement of the hydraulic brake booster. Do not order boosters for shelf stock. When a replacement is required, order the appropriate booster from GMSPO. All replaced boosters (excluding Export) must be returned to the Warranty Parts Center. Hold the booster until you receive the request for return. Special Tool Beginning February 18, 2005, each dealer was shipped a Hydro-Boost Checking Tool, CH 47950, for use in this recall. This tool is being furnished at no charge. Additional tools, if required, may be purchased by contacting SPX Kent-Moore at 1-800-468-6657. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9374 Claim Information Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification -- For Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- For US and Export (US States, Territories and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9375 of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Inspection Tools Required CH 47950 Hydro-Boost Checking Tool 1. With the vehicle transmission in PARK or NEUTRAL, set the park brake. 2. With the engine OFF, make a minimum of five (5) high effort brake applies until the pedal feels hard. 3. Start the engine. Important: DO NOT depress the brake pedal until instructed. 4. Turn the steering wheel to the "steering lock" (fully turned) position. Hold at the steering lock position for 1 to 2 seconds and then release the steering wheel. Repeat a total of 3 times. 5. Turn the vehicle off being careful not to step on the brake pedal. 6. For Express/Savana only: A. Remove the remote power steering reservoir mounting nuts. B. Disconnect the reservoir outlet hose from the booster unit. Keeping the hose end higher than the reservoir, reposition the reservoir forward and down out of the way. 7. Using a clean, lint-free shop cloth, wipe any dirt away from the steering pump supply hose/tube connection area on the hydro-boost (this is the center hose/tube of the three). 8. Disconnect the power steering supply hose/tube from the hydro-boost unit and wrap a clean lint-free shop cloth around the end of the hose and secure it in the engine compartment. 9. Using a clean lint-free shop cloth, clean any dirt off of the inlet port adapter valve assembly. Before installing the inlet port adapter, place a shop Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9376 cloth below the booster supply port in order to capture any fluid exiting the hydro-boost unit. 10. Install the inlet port adapter, CH 47950-2 (2) into the booster supply port. 11. Using a torque wrench, slowly tighten the inlet port adapter to 16 N.m (12 lb-ft). If the clear tube was removed from the inlet port adapter assembly, be sure it is reinstalled. 12. Before each use of the accumulator pressure clamp, CH 47950-1, be sure to grease the clamp bolt and anti rotation washer with wheel bearing grease. 13. Install the accumulator pressure clamp, CH 47950-1 (1), by sliding it over the accumulator and straddling the hydro-boost housing. 14. Confirm that the accumulator pressure clamp is squarely seated onto the booster housing and accumulator, and place the 3/4 inch containment bolt into the fixture. Install the nut hand-tight onto the containment bolt. 15. Check and make sure that the fixture washer is correctly positioned between the end of the accumulator, and that the pin is engaged in the end of the bolt. The tab on the washer should be rotated clockwise so it is located below the master cylinder mounting flange ear. Caution: Incorrect installation of the washer will result in damage to the accumulator end. 16. Hand-tighten the accumulator pressure clamp bolt. Make sure the clamp is level and the tube is square to the end of the accumulator. 17. Place a shop cloth next to the opening of the inlet port adapter in order to capture any fluid exiting the hydro-boost unit. Important: Do not exceed 65 N.m (48 lb-ft) torque. Important: A torque wrench must be used to tighten the fixture clamp bolt 18. Slowly tighten the fixture clamp bolt while monitoring the inlet port adapter tube for signs of power steering fluid. Stop tightening of the bolt when either fluid is observed (below the maximum 65 N.m (48 lb-ft) torque) OR The 65 N.m (48 lb-ft) maximum bolt torque is achieved (with no fluid Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9377 visible in the clear adapter tube). If fluid is seen coming out of the inlet port adapter up to 65 Nm (48 lb-ft) maximum torque, the hydro-boost booster assembly is "OK", Proceed to Step 19. A. If NO fluid is seen exiting from the inlet port adapter, complete Steps 19-27 and then repeat Steps 1-18. B. If no fluid is visible from the second evaluation, replace the hydro-boost unit. Proceed to the appropriate procedure found in this bulletin. 19. Loosen the clamp bolt, remove the clamp containment bolt, and remove the accumulator pressure clamp. Remove the inlet port adapter from the supply port of the booster. Wipe the excess power steering fluid off of the adapter with a clean, lint-free shop cloth. Store the adapter in a clean location, such as a plastic bag. 20. Reinstall the supply hose/tube to the booster. Tighten Tighten to 28 N.m (21 lb-ft). 21. Clean any spilled fluid from the outside of the booster. 22. For Express/Savana only: ^ Connect the reservoir outlet hose to the booster unit. Keeping the hose end higher than reservoir, reposition the reservoir onto the mounting studs. A. Install the remote power steering reservoir mounting nuts. Tighten Tighten to 7 Nm (58 lb in). 23. Start the engine and run at idle. Depress the brake pedal 5 times. Turn the steering wheel to the "steering lock" position. Hold for 1-2 seconds. Check to see if there is any leakage from the ports/fittings. 24. Turn the engine off. 25. If leaks were observed, re-check that the fittings are at the recommended torque values. Repeat Steps 17 and 18. 26. Check the power steering reservoir fluid level, add fluid if necessary. 27. Close the hood. Hydro-Boost(R) Replacement - Avalanche, Express, Savana, Silverado, Sierra, Suburban, Yukon XL Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Apply the park brake and block the wheels. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9378 2. Remove the master cylinder from the booster. Do not remove the pipes from the master cylinder. Set the master cylinder aside in the engine compartment. 3. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 4. Disconnect the electrical connector from the stop lamp switch. 5. Remove the retainer from the brake pedal pin. 6. Remove the stop lamp switch and the pushrod to the power brake booster from the brake pedal pin. 7. Unsnap the stop lamp switch from the power brake booster pushrod. 8. Remove the 4 booster to bulkhead nuts. 9. Remove the booster assembly. 10. Remove the gasket. Installation Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9379 1. Install the gasket. 2. Install the booster assembly. 3. Install the 4 booster to bulkhead nuts. Tighten Tighten the nuts to 36 N.m (26 lb-ft). 4. Snap the stop lamp switch onto the pushrod to the power brake booster. 5. Install the stop lamp switch with the pushrod on the brake pedal pin. 6. Install the brake switch retainer. 7. Connect the electrical connector to the stop lamp switch. 8. Install the master cylinder to the booster. 9. Install the master cylinder mounting nuts. Tighten Tighten the nuts to 36 N.m (27 lb-ft). 10. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9380 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kPa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove J 43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Hydro-Boost(R) Replacement -- Kodiak, TopKick Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Block the wheels. 2. Disconnect the electrical connectors from the electrohydraulic pump and the flow switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9381 3. Remove the master cylinder nuts. Do not remove the pipes from the master cylinder. Position the master cylinder away from the booster head. Secure the master cylinder in an upright position. 4. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 5. Remove the booster pump rod retainer from the lever. 6. Remove the stop lamp switch from the lever. 7. Remove the booster pump rod from the lever. 8. Remove the nuts at the booster. 9. Remove the booster assembly. Installation 1. Install the booster assembly to the vehicle. 2. Install the nuts at the booster. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9382 Tighten Tighten the nuts to 50 N.m (37 lb-ft). 3. Install the booster pump rod to the lever. 4. Install the stop lamp switch to the lever. 5. Install the booster pump rod retainer. 6. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). 7. Install the master cylinder. 8. Install the mounting nuts. Tighten Tighten the mounting bolts to 50 Nm (37 lb-ft). 9. Install the electrical connectors to the electrohydraulic pump and the flow switch. 10. Fill the hydraulic pump reservoir. Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9383 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kpa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove 1 J43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9384 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9385 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Recalls for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9386 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking Technical Service Bulletin # 05006 Date: 050323 Recall - Brake Booster Pressure Accumulator Cracking Product Safety - Hydro-Boost Accumulator Over-Pressurization # 05006 - (Mar 23, 2005) Models: 2004 Chevrolet Kodiak 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban 2004 GMC TopKick 2004-2005 GMC Savana, Sierra, Yukon XL Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Yukon XL vehicles. On some of these vehicles, the hydraulic brake booster's pressure accumulator may crack and/or separate from the Hydro-Boost(R) assembly during normal vehicle operating conditions. If a separation were to occur and the hood of the vehicle were open, fragments from the accumulator could cause injury to people in the immediate area. In addition, the presence of this crack or fractured surface could allow the hydraulic fluid to leak from the accumulator circuit of the booster assembly. The loss of fluid would cause increased steering and braking effort. Correction Dealers are to inspect the hydraulic brake booster, and replace it if necessary. Vehicles Involved Involved are certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9392 Yukon XL vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information A very small number of vehicles (less than 90 world-wide) will require the replacement of the hydraulic brake booster. Do not order boosters for shelf stock. When a replacement is required, order the appropriate booster from GMSPO. All replaced boosters (excluding Export) must be returned to the Warranty Parts Center. Hold the booster until you receive the request for return. Special Tool Beginning February 18, 2005, each dealer was shipped a Hydro-Boost Checking Tool, CH 47950, for use in this recall. This tool is being furnished at no charge. Additional tools, if required, may be purchased by contacting SPX Kent-Moore at 1-800-468-6657. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9393 Claim Information Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification -- For Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- For US and Export (US States, Territories and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9394 of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Inspection Tools Required CH 47950 Hydro-Boost Checking Tool 1. With the vehicle transmission in PARK or NEUTRAL, set the park brake. 2. With the engine OFF, make a minimum of five (5) high effort brake applies until the pedal feels hard. 3. Start the engine. Important: DO NOT depress the brake pedal until instructed. 4. Turn the steering wheel to the "steering lock" (fully turned) position. Hold at the steering lock position for 1 to 2 seconds and then release the steering wheel. Repeat a total of 3 times. 5. Turn the vehicle off being careful not to step on the brake pedal. 6. For Express/Savana only: A. Remove the remote power steering reservoir mounting nuts. B. Disconnect the reservoir outlet hose from the booster unit. Keeping the hose end higher than the reservoir, reposition the reservoir forward and down out of the way. 7. Using a clean, lint-free shop cloth, wipe any dirt away from the steering pump supply hose/tube connection area on the hydro-boost (this is the center hose/tube of the three). 8. Disconnect the power steering supply hose/tube from the hydro-boost unit and wrap a clean lint-free shop cloth around the end of the hose and secure it in the engine compartment. 9. Using a clean lint-free shop cloth, clean any dirt off of the inlet port adapter valve assembly. Before installing the inlet port adapter, place a shop Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9395 cloth below the booster supply port in order to capture any fluid exiting the hydro-boost unit. 10. Install the inlet port adapter, CH 47950-2 (2) into the booster supply port. 11. Using a torque wrench, slowly tighten the inlet port adapter to 16 N.m (12 lb-ft). If the clear tube was removed from the inlet port adapter assembly, be sure it is reinstalled. 12. Before each use of the accumulator pressure clamp, CH 47950-1, be sure to grease the clamp bolt and anti rotation washer with wheel bearing grease. 13. Install the accumulator pressure clamp, CH 47950-1 (1), by sliding it over the accumulator and straddling the hydro-boost housing. 14. Confirm that the accumulator pressure clamp is squarely seated onto the booster housing and accumulator, and place the 3/4 inch containment bolt into the fixture. Install the nut hand-tight onto the containment bolt. 15. Check and make sure that the fixture washer is correctly positioned between the end of the accumulator, and that the pin is engaged in the end of the bolt. The tab on the washer should be rotated clockwise so it is located below the master cylinder mounting flange ear. Caution: Incorrect installation of the washer will result in damage to the accumulator end. 16. Hand-tighten the accumulator pressure clamp bolt. Make sure the clamp is level and the tube is square to the end of the accumulator. 17. Place a shop cloth next to the opening of the inlet port adapter in order to capture any fluid exiting the hydro-boost unit. Important: Do not exceed 65 N.m (48 lb-ft) torque. Important: A torque wrench must be used to tighten the fixture clamp bolt 18. Slowly tighten the fixture clamp bolt while monitoring the inlet port adapter tube for signs of power steering fluid. Stop tightening of the bolt when either fluid is observed (below the maximum 65 N.m (48 lb-ft) torque) OR The 65 N.m (48 lb-ft) maximum bolt torque is achieved (with no fluid Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9396 visible in the clear adapter tube). If fluid is seen coming out of the inlet port adapter up to 65 Nm (48 lb-ft) maximum torque, the hydro-boost booster assembly is "OK", Proceed to Step 19. A. If NO fluid is seen exiting from the inlet port adapter, complete Steps 19-27 and then repeat Steps 1-18. B. If no fluid is visible from the second evaluation, replace the hydro-boost unit. Proceed to the appropriate procedure found in this bulletin. 19. Loosen the clamp bolt, remove the clamp containment bolt, and remove the accumulator pressure clamp. Remove the inlet port adapter from the supply port of the booster. Wipe the excess power steering fluid off of the adapter with a clean, lint-free shop cloth. Store the adapter in a clean location, such as a plastic bag. 20. Reinstall the supply hose/tube to the booster. Tighten Tighten to 28 N.m (21 lb-ft). 21. Clean any spilled fluid from the outside of the booster. 22. For Express/Savana only: ^ Connect the reservoir outlet hose to the booster unit. Keeping the hose end higher than reservoir, reposition the reservoir onto the mounting studs. A. Install the remote power steering reservoir mounting nuts. Tighten Tighten to 7 Nm (58 lb in). 23. Start the engine and run at idle. Depress the brake pedal 5 times. Turn the steering wheel to the "steering lock" position. Hold for 1-2 seconds. Check to see if there is any leakage from the ports/fittings. 24. Turn the engine off. 25. If leaks were observed, re-check that the fittings are at the recommended torque values. Repeat Steps 17 and 18. 26. Check the power steering reservoir fluid level, add fluid if necessary. 27. Close the hood. Hydro-Boost(R) Replacement - Avalanche, Express, Savana, Silverado, Sierra, Suburban, Yukon XL Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Apply the park brake and block the wheels. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9397 2. Remove the master cylinder from the booster. Do not remove the pipes from the master cylinder. Set the master cylinder aside in the engine compartment. 3. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 4. Disconnect the electrical connector from the stop lamp switch. 5. Remove the retainer from the brake pedal pin. 6. Remove the stop lamp switch and the pushrod to the power brake booster from the brake pedal pin. 7. Unsnap the stop lamp switch from the power brake booster pushrod. 8. Remove the 4 booster to bulkhead nuts. 9. Remove the booster assembly. 10. Remove the gasket. Installation Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9398 1. Install the gasket. 2. Install the booster assembly. 3. Install the 4 booster to bulkhead nuts. Tighten Tighten the nuts to 36 N.m (26 lb-ft). 4. Snap the stop lamp switch onto the pushrod to the power brake booster. 5. Install the stop lamp switch with the pushrod on the brake pedal pin. 6. Install the brake switch retainer. 7. Connect the electrical connector to the stop lamp switch. 8. Install the master cylinder to the booster. 9. Install the master cylinder mounting nuts. Tighten Tighten the nuts to 36 N.m (27 lb-ft). 10. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9399 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kPa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove J 43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Hydro-Boost(R) Replacement -- Kodiak, TopKick Tools Required ^ J 35555 Metal Mityvac ^ J 43485 Power Steering Bleeder Adapter Removal 1. Block the wheels. 2. Disconnect the electrical connectors from the electrohydraulic pump and the flow switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9400 3. Remove the master cylinder nuts. Do not remove the pipes from the master cylinder. Position the master cylinder away from the booster head. Secure the master cylinder in an upright position. 4. Disconnect the power brake booster inlet hose, the steering gear inlet hose, and the power brake booster outlet hose from the booster assembly. 5. Remove the booster pump rod retainer from the lever. 6. Remove the stop lamp switch from the lever. 7. Remove the booster pump rod from the lever. 8. Remove the nuts at the booster. 9. Remove the booster assembly. Installation 1. Install the booster assembly to the vehicle. 2. Install the nuts at the booster. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9401 Tighten Tighten the nuts to 50 N.m (37 lb-ft). 3. Install the booster pump rod to the lever. 4. Install the stop lamp switch to the lever. 5. Install the booster pump rod retainer. 6. Connect the power brake booster outlet hose, the steering gear inlet hose, and the power brake booster inlet hose. Tighten ^ Tighten the power brake booster inlet hose to 28 N.m (20 lb-ft). ^ Tighten the steering gear inlet hose to 28 N.m (20 lb-ft). 7. Install the master cylinder. 8. Install the mounting nuts. Tighten Tighten the mounting bolts to 50 Nm (37 lb-ft). 9. Install the electrical connectors to the electrohydraulic pump and the flow switch. 10. Fill the hydraulic pump reservoir. Important: Maintain the fluid level throughout the bleed procedure. 11. Remove the pump reservoir cap. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9402 Use clean, new power steering fluid only. 12. Fill the pump reservoir with fluid to the FULL COLD level. 13. Attach J 43485, Power Steering Bleeder Adapter, to J 35555, Metal Mityvac, or equivalent. 14. Place J 43485 on or in the pump reservoir filler neck. 15. Apply a vacuum of 68 kpa (20 in Hg) maximum. 16. Wait 1 minute. 17. Remove 1 J43485 and J 35555. 18. Reinstall the pump reservoir cap. 19. Start the engine. Allow the engine to idle. 20. Turn the steering wheel 180-360 degrees in both directions 5 times. 21. Switch the ignition off 22. Verify the fluid level. 23. Release the park brake and unblock the wheels. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9403 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9404 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Fluid Accumulator: > 05006 > Mar > 05 > Recall - Brake Booster Pressure Accumulator Cracking > Page 9405 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Page 9406 Hydraulic Fluid Accumulator: Service and Repair Hydraulic Brake Booster Accumulator Replacement ^ Tools Required J 26889 Accumulator Piston Compressor Removal Procedure Caution: The accumulator contains compressed gas. Always use the proper tools and follow the recommended procedures or personal injury may result. Do not apply heat to accumulator. Do not attempt to repair an inoperative accumulator. Always replace an inoperative accumulator with a new one. Dispose of an inoperative accumulator by drilling a 1.5 mm (1/16 inch) diameter hole through the end of the accumulator can, opposite the O-ring. Caution: Push rod removal is not recommended. Improper staking of the push rod to the Hydroboost reaction piston can result in a loss of brakes. If the rod or seals require service, the entire unit must be replaced. 1. Apply the park brake and block the wheels. 2. Depress brake pedal at least 10 times in order to relieve pressure in the accumulator. 3. Remove the master cylinder from the hydraulic booster. 4. Place the J 26889 over the end of the accumulator. 5. Install the nut on the stud. 6. Depress the accumulator with a C-clamp. If the accumulator does not move with moderate pressure, remove the C-clamp and depress the brake pedal ten times in order to relieve pressure in the accumulator. 7. Rotate the retaining ring (2) until either end of the ring is under the access hole (1). 8. Depress and hold the retaining ring (2) with a small tool inserted into the access hole (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Page 9407 9. Remove the accumulator retainer ring (1) using a small hook shaped tool. 10. Release the C-clamp. 11. Remove the nut from the stud. 12. Remove the J 26889. 13. Remove the accumulator (2) and the O-ring seal (3). Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Page 9408 1. Lubricate all of the seals and the metal friction points with power steering fluid. 2. Install the accumulator (2) and the O-ring seal (3). 3. Place the J 26889 over the end of the accumulator. 4. Install the nut on the stud. 5. Depress the accumulator with a C-clamp. 6. Install the accumulator retainer ring (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Technical Service Bulletins > Page 9409 7. Release the C-clamp. 8. Remove the nut from the stud. 9. Remove the J 26889. 10. Install the master cylinder to the hydraulic booster. 11. Release the park brake and unblock the wheels. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair Vacuum Brake Booster: Service and Repair Vacuum Brake Booster Replacement Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Apply the park brake and block the wheels. 2. Remove the brake master cylinder. 3. Remove the vacuum hose from the brake booster check valve. 4. Remove the pushrod retaining clip (4) from the brake pedal stud (1). 5. Remove the stop lamp switch (2) and the pushrod (3) from the brake pedal stud (1). 6. Remove the 4 vacuum booster mounting nuts. 7. Remove the vacuum booster. 8. Remove the gasket from the booster and discard. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Page 9413 1. Install the gasket to the booster. 2. Install the vacuum booster. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the 4 vacuum booster mounting nuts. ^ Tighten the nuts to 33 Nm (24 ft. lbs.). 4. Install the pushrod (3) and the stop lamp switch (2) to the brake pedal stud (1). 5. Install the pushrod retaining clip (4) to the brake pedal stud (1). 6. Install the vacuum hose to the brake booster check valve. 7. Install the master cylinder. 8. Release the park brake and unblock the wheels. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Service and Repair Vacuum Brake Booster Check Valve: Service and Repair Vacuum Brake Booster Check Valve and/or Hose Replacement Removal Procedure 1. Remove the vacuum brake booster check valve from the vacuum brake booster. 2. Remove the vacuum brake booster hose clamp at the check valve. 3. Remove the vacuum brake booster check valve from the hose. 4. Remove the manifold sight shield (4.8L, 5.3L, 6.0L). 5. Disconnect the vacuum brake booster hose at the engine (4.8L, 5.3L, 6.0L). 6. Disconnect the vacuum brake booster hose at the engine (4.3L). 7. Remove the vacuum brake booster hose from the vehicle. Installation Procedure 1. Connect the vacuum brake booster hose at the engine (4.8L, 5.3L, 6.0L). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Service and Repair > Page 9417 2. Connect the vacuum brake booster hose at the engine (4.3L). 3. Install the manifold sight shield (4.8L, 5.3L, 6.0L). 4. Install the vacuum brake booster check valve to the hose. 5. Install the vacuum brake booster hose clamp to the check valve. 6. Install the vacuum brake booster check valve to the vacuum brake booster. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Service and Repair Vacuum Pump: Service and Repair Brake Assist Pump Motor Replacement Removal Procedure 1. Remove the vacuum hose from the brake assist pump. 2. Disconnect the electrical connector. 3. Remove the brake assist pump nuts. 4. Remove the brake assist pump from the booster by pulling the inlet tube out of the grommet. Installation Procedure 1. Install the brake assist pump to the booster by pushing the inlet tube into the grommet and aligning the studs to the holes. 2. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Service and Repair > Page 9421 Install the brake assist pump nuts. ^ Tighten the nuts to 18 Nm (13 ft. lbs.). 3. Connect the electrical connector. 4. Install the vacuum hose to the brake assist pump. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 9431 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 04-05-25-005A > Sep > 04 > Brakes - ABS Lamp/Service Brake System Message ON Electronic Brake Control Module: Customer Interest Brakes - ABS Lamp/Service Brake System Message ON Bulletin No.: 04-05-25-005A Date: September 28, 2004 ADVANCE SERVICE INFORMATION RESOLUTION Subject: Antilock Brake System (ABS) Light On, Service Brake System Message on Driver Information Center (DIC) (Reprogram Electronic Brake Control Module (EBCM)) Models: 2003-2005 Chevrolet Silverado 2500/3500 HD Series Pickups 2003-2005 GMC Sierra 2500/3500 HD Series Pickups with Identification 2-inch Body Raise, HD Model (RPO HVY) Supercede: This bulletin is being revised to add correction information and additional model years. Please discard Advanced Service Information Bulletin Number 04-05-25-005 (Section 05 - Brakes). Condition Some customers may comment that the ABS light, Service Brake System message comes on intermittently during initial start-up. The condition does not cause a DTC to be stored permanently. Cause The cause may be a timing issue related to the cranking/starting of the vehicles. It appears that the condition is more likely to occur on vehicles with diesel engines, though it can occur on vehicles with gasoline engines as well. Correction Reprogram the EBCM with TIS software version 7.5, released July 26, 2004 or newer. Refer to Service Programming System (SPS). Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 04-05-25-005A > Sep > 04 > Brakes - ABS Lamp/Service Brake System Message ON > Page 9436 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 9442 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 04-05-25-005A > Sep > 04 > Brakes - ABS Lamp/Service Brake System Message ON Electronic Brake Control Module: All Technical Service Bulletins Brakes - ABS Lamp/Service Brake System Message ON Bulletin No.: 04-05-25-005A Date: September 28, 2004 ADVANCE SERVICE INFORMATION RESOLUTION Subject: Antilock Brake System (ABS) Light On, Service Brake System Message on Driver Information Center (DIC) (Reprogram Electronic Brake Control Module (EBCM)) Models: 2003-2005 Chevrolet Silverado 2500/3500 HD Series Pickups 2003-2005 GMC Sierra 2500/3500 HD Series Pickups with Identification 2-inch Body Raise, HD Model (RPO HVY) Supercede: This bulletin is being revised to add correction information and additional model years. Please discard Advanced Service Information Bulletin Number 04-05-25-005 (Section 05 - Brakes). Condition Some customers may comment that the ABS light, Service Brake System message comes on intermittently during initial start-up. The condition does not cause a DTC to be stored permanently. Cause The cause may be a timing issue related to the cranking/starting of the vehicles. It appears that the condition is more likely to occur on vehicles with diesel engines, though it can occur on vehicles with gasoline engines as well. Correction Reprogram the EBCM with TIS software version 7.5, released July 26, 2004 or newer. Refer to Service Programming System (SPS). Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 04-05-25-005A > Sep > 04 > Brakes - ABS Lamp/Service Brake System Message ON > Page 9447 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 9448 Electronic Brake Control Module: Locations ABS Component Views Electronic Brake Control Module (EBCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 9449 Electronic Brake Control Module: Diagrams ABS Connector End Views Electronic Brake Control Module (ECBCM) - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 9450 Electronic Brake Control Module (ECBCM) - C2 (10/20 Series w/o HP2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 9451 Electronic Brake Control Module (ECBCM) - C2 (30 Series and HP2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 9452 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. 3. Important: The area around the EHCU MUST be free from loose dirt to prevent contamination of disassembled ABS components. Thoroughly wash all contaminants from around the EHCU. 4. Disconnect the chassis electrical connectors from the EBCM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 9453 5. Remove the mounting screws (1) that fasten the EBCM (2) to the BPMV (3). 6. Remove the EBCM (2) from the BPMV (3). Removal may require a light amount of force. Notice: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 9454 7. Disconnect the BPMV electrical connector from the EBCM. 8. Clean the BPMV to EBCM mounting surfaces with a clean cloth. Installation Procedure Important: ^ Do not reuse the old mounting screws. Always install new mounting screws with the new EBCM. ^ Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 1. Connect the BPMV electrical connector to the EBCM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 9455 2. Install the EBCM to the BPMV. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the new screws (1) in the EBCM (2). ^ Tighten the screws to 5 Nm (39 inch lbs.) in an X-pattern. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 9456 4. connect the chassis electrical connectors to the EBCM. 5. Lower the vehicle. 6. Connect the negative battery cable. 7. Revise the tire calibration using the Scan Tool Tire Size Calibration function. 8. Return to Diagnostic Starting Point - Antilock Brake System. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Remove the MID-bussed electrical center from the bracket. 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch mounting bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Page 9461 1. Install the park brake warning lamp switch. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake warning lamp switch mounting bolt. ^ Tighten the bolt to 3 Nm (25 inch lbs.). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the MID-bussed electrical center to the bracket. 5. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations Traction Control Switch: Locations ABS Component Views Traction Control Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 9465 Traction Control Switch: Diagrams ABS Connector End Views Traction Control Switch (NW7) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 9466 Traction Control Switch: Service and Repair Traction Control Switch Replacement Removal Procedure 1. Remove instrument panel (IP) bezel. 2. Gently lift the switch retaining tabs (1) and remove the traction control switch (2) from the instrument panel (IP) assembly (3). 3. Disconnect the harness connector from the traction control switch. Installation Procedure 1. Connect the harness connector to the traction control switch. 2. Install the traction control switch (2) into the instrument panel (IP) assembly (3), making sure that all of the switch retaining tabs (1) are engaged. 3. Install instrument panel (IP) bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: Customer Interest Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set > Page 9475 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set Wheel Speed Sensor: All Technical Service Bulletins Brakes - Low Speed ABS Activation/No DTC's Set TECHNICAL Bulletin No.: 03-05-25-007D Date: May 01, 2009 Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2006 Chevrolet Silverado 2001-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 2003-2006 Chevrolet Express 2007 Chevrolet Silverado Classic 1999-2006 GMC Sierra 2001-2006 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2003-2006 GMC Savana 2007 GMC Sierra Classic 2003-2006 HUMMER H2 .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the 2007 Silverado/Sierra Classic models. Please discard Corporate Bulletin Number 03-05-25-007C (Section 05 - Brakes). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean the wheel speed sensor mounting surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual. 2. Disconnect both the front wheel speed sensor connectors at the frame and harness. 3. Place a Digital Volt Meter (DVM) across the terminals of each wheel speed sensor connector. 4. Rotate the wheel clockwise approximately one revolution per second. The minimum reading should be at least 350 ACmV's. If the reading is less than 350 ACmV's, remove the wheel speed sensor. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 5. Plug the wheel speed sensor bore in order to prevent debris from falling into the hub during service. 6. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, scotch brite, or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 7. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 8. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (in Canada, P/N 89022218). 9. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor O-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (in Canada, P/N 993037). 10. Install either the original sensor or a new one in the hub. Ensure that the sensor is seated flush against the hub. Refer to the applicable Wheel Speed Sensor Replacement procedure in the ABS sub-section of the Service Manual. 11. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel. The voltage should now read at least 350 ACmV's. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 03-05-25-007D > May > 09 > Brakes - Low Speed ABS Activation/No DTC's Set > Page 9481 Parts Information Place unused material on dealer shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 9482 Wheel Speed Sensor: Locations ABS Component Views Wheel Speed Sensor (WSS) - RF and LF Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 9483 Wheel Speed Sensor: Diagrams ABS Connector End Views Wheel Speed Sensor (WSS) - LF Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 9484 Wheel Speed Sensor (WSS) - RF Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 9485 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (4WD) Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and wheel. 3. Remove the brake rotor (2) shown on the 1500 series. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the WSS cable mounting clip from the knuckle. 5. Remove the WSS cable mounting clip from the upper control arm. 6. Remove the WSS cable mounting clip from the frame attachment point. 7. Remove the WSS cable electrical connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 9486 8. Remove the wheel speed sensor (WSS) mounting bolt. 9. NOTICE: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. Remove the wheel speed sensor (5) from the hub/bearing assembly (4) shown on the 2500/3500 series. Installation Procedure 1. Plug the WSS bore to prevent debris from falling into the hub. 2. Using a wire brush or equivalent, clean the WSS mounting surface on the hub to remove any rust or corrosion. 3. Apply a thin layer of wheel bearing lubricant, GM P/N 01051344 to the hub surface and the sensor O-ring prior to sensor installation. 4. Install the WSS (5) into the hub/bearing assembly (4) shown on the 2500/3500 series. Ensure that the sensor is seated flat against the hub. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 9487 5. Notice: Refer to Fastener Notice in Service Precautions. Install the WSS mounting bolt. ^ Tighten the WSS mounting bolt to 18 Nm (13 ft. lbs.). 6. Install the WSS cable mounting clip to the knuckle. 7. Install the WSS cable mounting clip to the upper control arm. 8. Install the WSS cable mounting clip to the frame attachment point. 9. Connect the WSS cable electrical connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 9488 10. Install the brake rotor (2) shown on the 1500 series. Refer to Brake Rotor Replacement - Front in Disc Brakes. 11. Install the tire and wheel. 12. Perform the Diagnostic System Check - ABS. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams Clutch Start Switch (M/T) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions Jump Starting: Service Precautions CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. - Flush any contacted areas with water immediately and thoroughly. - Get medical help. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions > Page 9498 Jump Starting: Service and Repair JUMP STARTING IN CASE OF EMERGENCY (NON HP2) CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. - Flush any contacted areas with water immediately and thoroughly. - Get medical help. NOTE: This vehicle has a 12 volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. This vehicle has a 12-volt positive, negative ground electrical system. Do not try to jump start a vehicle, if you are unsure of the other vehicle's positive voltage or ground position. The booster battery and the discharged battery should be treated carefully when using jumper cables. 1. Position the vehicle with the booster battery so that the jumper cables will comfortably reach the battery of the other vehicle. - Do not let the 2 vehicles touch. - Make sure that the jumper cables do not have loose clamps or missing insulation. 2. Perform the following steps on both vehicles: 2.1. Place the automatic transmission in PARK. 2.2. Block the wheels. 2.3. Set the parking brake. 2.4. Turn off all electrical loads that are not needed-Leave the hazard flashers ON. 2.5. Turn OFF the ignition switch. IMPORTANT: Some vehicles have a battery remote positive stud-ALWAYS use the battery remote positive stud in order to give or to receive a jump start-Consult the vehicle's owner's manual for proper connections. 3. Attach the end of one jumper cable to the positive terminal of the discharged battery. 4. Attach the other end of the first cable to the positive terminal of the booster battery. 5. Attach one end of the remaining jumper cable to the negative terminal of the booster battery. NOTE: Do not connect the negative charger lead to the housings of other vehicle electrical accessories or equipment. The action of the battery charger may damage such equipment. 6. Make the final connection of the negative jumper cable to the block or suitable bracket connected directly to the block, away from the battery. 7. Start the engine of the vehicle that is providing the jump start and turn off all electrical accessories. Raise the engine RPM to approximately 1,500 RPM. 8. Crank the engine of the vehicle with the weak battery. If the engine does not crank or cranks too slowly, perform the following steps: 8.1. Turn the ignition OFF. 8.2. Allow the booster vehicle engine to run at approximately 1,500 RPM for 5 minutes. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions > Page 9499 8.3. Attempt to start the engine of the vehicle with the discharged battery. 9. Reverse the steps exactly when removing the jumper cables. The negative battery cable must first be disconnected from the engine that was jump started. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Disconnect/Connect Procedure (Single Battery) Negative: Service and Repair Disconnect/Connect Procedure (Single Battery) BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE (SINGLE BATTERY) REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Record the customer's pre-set radio stations. 2. Turn off all the lamps and accessories. 3. Turn the ignition OFF. 4. Loosen the negative battery cable bolt. 5. Remove the negative battery cable. INSTALLATION PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. IMPORTANT: Clean any existing corrosion from the battery terminal bolt flange and battery cable end. 1. Install the negative battery cable. NOTE: Refer to Fastener Notice in Service Precautions. 2. Tighten the negative battery cable bolt. Tighten Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Disconnect/Connect Procedure (Single Battery) > Page 9505 Tighten the bolt to 17 N.m (13 lb ft). 3. Re-set the customer's radio stations. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Disconnect/Connect Procedure (Single Battery) > Page 9506 Negative: Service and Repair Disconnect/Connect Procedure (Auxiliary Battery) BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE (AUXILIARY BATTERY) REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Turn off all the lamps and accessories. 2. Turn the ignition OFF. 3. Loosen the negative battery cable bolt. 4. Remove the negative battery cable. INSTALLATION PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. IMPORTANT: Clean any existing corrosion from the battery terminal bolt flange and battery cable end. 1. Install the negative battery cable. NOTE: Refer to Fastener Notice in Service Precautions. 2. Tighten the negative battery cable bolt. Tighten Tighten the bolt to 17 N.m (13 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Disconnect/Connect Procedure (Single Battery) > Page 9507 Negative: Service and Repair Replacement Procedure - Auxiliary BATTERY NEGATIVE CABLE REPLACEMENT - AUXILIARY REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the auxiliary battery negative cable (2). 2. Unsnap the positive battery cable cap. 3. Disconnect the positive battery cable (1). 4. Remove the auxiliary battery cable clip from the fender wheelhouse inner panel. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Remove the cable clip bolt (5) at the frame. 7. Remove the auxiliary battery negative cable bolt (4). 8. Remove the battery cable retainer nut (6) and the retainer. 9. Remove the battery positive cable from the retainer. 10. Remove the positive battery cable nut (7). 11. Remove the positive battery cable lead (8) from the starter. 12. Remove the auxiliary battery cable. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Disconnect/Connect Procedure (Single Battery) > Page 9508 1. Install the auxiliary battery cable. 2. Install the positive battery cable lead (8) to the starter. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the positive battery cable nut (7). Tighten Tighten the nut to 9 N.m (80 lb in). 4. Install the battery positive cable to the retainer. 5. Install the battery cable retainer nut (6) and the retainer. Tighten Tighten the nut to 12 N.m (106 lb in). 6. Install the auxiliary battery negative cable bolt (4). Tighten Tighten the bolt to 34 N.m (25 lb ft). 7. Install the cable clip bolt (5) to the frame. Tighten Tighten the bolt to 21 N.m (16 lb ft). 8. Lower the vehicle. 9. Install the auxiliary battery cable clip to the fender wheelhouse inner panel. 10. Connect the positive battery cable (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Disconnect/Connect Procedure (Single Battery) > Page 9509 Tighten Tighten the bolt to 17 N.m (13 lb ft). 11. Snap the positive battery cable cap closed. 12. Connect the auxiliary battery negative cable (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Disconnect/Connect Procedure (Single Battery) > Page 9510 Negative: Service and Repair Replacement procedure BATTERY NEGATIVE CABLE REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the negative cable clip (1) from the power steering pump bracket. 3. Remove the negative cable from the positive cable clip. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Remove the negative battery cable bolt (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Disconnect/Connect Procedure (Single Battery) > Page 9511 6. Remove the forward lamp wiring harness ground/negative cable bolt (3). 7. Remove the negative battery cable (1). INSTALLATION PROCEDURE 1. Install the negative battery cable (1). 2. Position the negative cable and forward lamp wiring harness ring terminals to the frame. 3. Insert the anti-rotation tab on the forward lamp wiring harness (2) into the hole in the frame. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the forward lamp wiring harness ground/negative cable bolt (3). Tighten Tighten the bolt to 9 N.m (80 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Disconnect/Connect Procedure (Single Battery) > Page 9512 5. Position the negative cable and engine wiring harness ring terminals to the engine block. 6. Position the anti-rotation tab on the negative cable (2) in the correct location. 7. Install the engine wiring harness ground/negative cable bolt (1). Tighten Tighten the bolt to 34 N.m (25 lb ft). 8. Lower the vehicle. 9. Install the negative cable to the positive cable clip. 10. Install the negative cable clip (1) to the power steering pump bracket. 11. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service Precautions > Technician Safety Information Positive: Technician Safety Information CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. - Flush any contacted areas with water immediately and thoroughly. - Get medical help. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service Precautions > Technician Safety Information > Page 9517 Positive: Vehicle Damage Warnings BATTERY DISCONNECT CAUTION CAUTION: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure - Battery to Battery Relay - Auxiliary Positive: Service and Repair Replacement Procedure - Battery to Battery Relay - Auxiliary BATTERY POSITIVE CABLE REPLACEMENT - BATTERY TO BATTERY RELAY - AUXILIARY REMOVAL PROCEDURE 1. Remove the auxiliary battery. 2. Unclip the mega fuse from the auxiliary battery tray. 3. Remove the auxiliary positive cable to relay nut (2). 4. Remove the auxiliary battery positive cable. INSTALLATION PROCEDURE 1. Install the auxiliary battery positive cable. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the auxiliary positive cable to relay nut (2). Tighten Tighten the nut to 9 N.m (80 lb in). 3. Clip the mega fuse to the auxiliary battery tray. 4. Install the auxiliary battery. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure - Battery to Battery Relay - Auxiliary > Page 9520 Positive: Service and Repair Replacement Procedure- Battery Relay to Starter - Auxiliary BATTERY POSITIVE CABLE REPLACEMENT - BATTERY RELAY TO STARTER - AUXILIARY REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the auxiliary battery negative cable. 2. Reposition the boot. 3. Remove the auxiliary positive battery cable nut. 4. Remove the auxiliary positive battery cable from the auxiliary relay. 5. Remove the auxiliary positive battery cable clip from the battery tray. 6. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 7. Remove the auxiliary cable clip bolt from the frame. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure - Battery to Battery Relay - Auxiliary > Page 9521 8. Remove the starter lead nut. 9. Remove the auxiliary positive battery cable from the starter stud. 10. Remove the auxiliary positive battery cable. INSTALLATION PROCEDURE 1. Install the auxiliary positive battery cable. 2. Install the auxiliary positive battery cable to the starter stud. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the starter lead nut. Tighten Tighten the nut to 9 N.m (80 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure - Battery to Battery Relay - Auxiliary > Page 9522 4. Install the auxiliary cable clip bolt to the frame. Tighten Tighten the bolt to 10 N.m (89 lb in). 5. Lower the vehicle. 6. Install the auxiliary positive battery cable clip to the battery tray. 7. Install the auxiliary positive battery cable to the auxiliary relay. 8. Install the auxiliary positive battery cable nut. Tighten Tighten the nut to 8 N.m (71 lb in). 9. Position the boot. 10. Connect the auxiliary battery negative cable Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure - Battery to Battery Relay - Auxiliary > Page 9523 Positive: Service and Repair Replacement procedure BATTERY POSITIVE CABLE REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable (2). 2. Unsnap the positive battery cable cap. 3. Disconnect the positive battery cable (1). IMPORTANT: The bolt is integral to the battery cable and is not removable. 4. Loosen the positive cable bolt at the underhood bussed electrical center (UBEC). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure - Battery to Battery Relay - Auxiliary > Page 9524 5. Unsnap the junction block cover. 6. Remove the positive cable (1) from the junction block. 7. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 8. Remove the clip attaching the positive cable to the negative cable. 9. Remove the battery cable channel bolts. 10. Remove the battery cable from the channel. 11. Remove the battery cable retainer nut (6) and the retainer. 12. Remove the battery positive cable from the retainer. 13. Remove the positive battery cable nut (7). 14. Remove the positive battery cable lead (8) from the starter. 15. Remove the positive battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure - Battery to Battery Relay - Auxiliary > Page 9525 INSTALLATION PROCEDURE 1. Install the positive battery cable. 2. Install the positive battery cable lead (8) to the starter. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the positive battery cable nut (7). Tighten Tighten the nut to 9 N.m (80 lb in). 4. Install the battery positive cable to the retainer. 5. Install the battery cable retainer nut (6) and the retainer. Tighten Tighten the nut to 12 N.m (106 lb in). 6. Install the battery cable to the channel. 7. Install the battery cable channel bolts. Tighten Tighten the bolts to 8 N.m (71 lb in). 8. Install the clip attaching the positive cable to the negative cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure - Battery to Battery Relay - Auxiliary > Page 9526 9. Lower the vehicle. 10. Install the positive cable (1) to the junction block. 11. Snap the junction block cover closed. IMPORTANT: The bolt is integral to the battery cable and is not removable. 12. Tighten the positive cable bolt at the UBEC. Tighten Tighten the bolt to 9 N.m (80 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure - Battery to Battery Relay - Auxiliary > Page 9527 13. Connect the positive battery cable (1). Tighten Tighten the bolt to 17 N.m (13 lb ft). 14. Snap the positive battery cable cap closed. 15. Connect the negative battery cable (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure - Battery to Battery Relay - Auxiliary > Page 9528 Positive: Service and Repair Replacement procedure - Auxiliary BATTERY POSITIVE CABLE REPLACEMENT - AUXILIARY REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the auxiliary battery negative cable . 2. Unsnap the positive battery cable cap. 3. Disconnect the positive battery cable (1). 4. Remove the auxiliary battery cable clip from the fender wheelhouse inner panel. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 6. Remove the cable clip bolt (5) at the frame. 7. Remove the auxiliary battery negative cable bolt (4). 8. Remove the battery cable retainer nut (6) and the retainer. 9. Remove the battery positive cable from the retainer. 10. Remove the positive battery cable nut (7). 11. Remove the positive battery cable lead (8) from the starter. 12. Remove the auxiliary battery cable. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure - Battery to Battery Relay - Auxiliary > Page 9529 1. Install the auxiliary battery cable. 2. Install the positive battery cable lead (8) to the starter. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the positive battery cable nut (7). Tighten Tighten the nut to 9 N.m (80 lb in). 4. Install the battery positive cable to the retainer. 5. Install the battery cable retainer nut (6) and the retainer. Tighten Tighten the nut to 12 N.m (106 lb in). 6. Install the auxiliary battery negative cable bolt (4). Tighten Tighten the bolt to 34 N.m (25 lb ft). 7. Install the cable clip bolt (5) to the frame. Tighten Tighten the bolt to 21 N.m (16 lb ft). 8. Lower the vehicle. 9. Install the auxiliary battery cable clip to the fender wheelhouse inner panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Replacement Procedure - Battery to Battery Relay - Auxiliary > Page 9530 10. Connect the positive battery cable (1). Tighten Tighten the bolt to 17 N.m (13 lb ft). 11. Snap the positive battery cable cap closed. 12. Connect the auxiliary battery negative cable (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Alternator - Incorrect Amperage Coding Alternator: Technical Service Bulletins Alternator - Incorrect Amperage Coding Bulletin No.: 04-06-03-001 Date: February 03, 2004 INFORMATION Subject: Incorrect Amp Code On Generator Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2003-2004 GMC Denali XL, Savana, Sierra, Yukon, Yukon XL 2003-2004 HUMMER H2 The purpose of this bulletin is to inform the technician of an incorrect Amp code stamped on the generator. The code on the side of the generator reads 130 A and it should read 145 A. The 130 A has been stamped on the generators in error and does not indicate the actual amperage of the generator. A 130 A generator is not produced for this vehicle. The correct replacement for the above vehicles is the generator with the 145 A marking. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Page 9536 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Page 9537 Generators Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions Alternator: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9540 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9541 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9542 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9543 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9544 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9545 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9546 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9547 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9548 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9549 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9550 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9551 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9552 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9553 Alternator: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9554 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9555 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9556 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9557 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9558 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9559 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9560 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9561 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9562 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9563 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9564 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9565 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9566 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9567 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9568 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9569 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9570 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9571 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9572 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9573 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9574 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9575 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9576 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9577 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9578 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9579 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9580 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9581 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9582 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9583 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9584 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9585 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9586 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9587 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9588 Alternator: Connector Views Generator - Left Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 9589 Generator - Right Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 9590 Alternator: Description and Operation GENERATOR The AD-230 and AD-244 generators are non-repairable. They are electrically similar to earlier models. The generators feature the following major components: The delta stator - The rectifier bridge - The rotor with slip rings and brushes - A conventional pulley - Dual internal fans - A voltage regulator The pulley and the fan cool the slip ring and the frame. The AD stands for air-cooled dual internal fan; the 2 is an electrical design designator; the 30/44 denotes the outside diameter of the stator laminations in millimeters, over 100 millimeters. The generators is rated at 102 and 130 amperes respectively. The generator features permanently lubricated bearings. Service should only include the tightening of mounting components. Otherwise, the generator is replaced as a complete unit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement Alternator: Service and Repair Generator Bracket Replacement GENERATOR BRACKET REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the air cleaner. 3. Remove the drive belt. 4. Remove the upper fan shroud. 5. Remove the electrical harness clip bolts. 6. Disconnect the generator electrical connector (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 9593 7. Remove the positive battery cable from the generator, perform the following: 7.1. Slide the boot (3) down to access the terminal stud. 7.2. Remove the positive cable nut (2). 7.3. Remove the positive cable. 8. Remove the drive belt tensioner bolt. 9. Remove the generator mounting bracket bolts. 10. Remove the generator mounting bracket. 11. If necessary, remove the idler pulleys. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 9594 NOTE: Refer to Fastener Notice in Service Precautions. 1. If necessary, install the idler pulleys. Tighten Tighten the bolts to 50 N.m (37 lb ft). 2. Install the generator mounting bracket. 3. Install the generator mounting bracket bolts. Tighten Tighten the bolts to 50 N.m (37 lb ft). 4. Install the drive belt tensioner bolt. Tighten Tighten the bolt to 50 N.m (37 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 9595 5. Install the positive battery cable to the generator, perform the following: 5.1. Install the positive cable. 5.2. Install the positive cable nut (2). Tighten Tighten the nut to 9 N.m (80 lb in). 5.3. Slide the boot (3) up to cover the terminal stud. 6. Connect the generator electrical connector (1). 7. Install the electrical harness clip bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 9596 8. Install the upper fan shroud. 9. Install the drive belt. 10. Install the air cleaner. 11. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 9597 Alternator: Service and Repair Generator Cable Replacement GENERATOR CABLE REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. If necessary, remove the engine sight shield. 3. Remove the generator cable from the generator, perform the following: 3.1. Reposition the boot to expose the stud. 3.2. Remove the generator cable nut. 3.3. Remove the generator cable from the stud. 4. Open the positive cable junction block. 5. Remove the generator cable nut. 6. Remove the generator cable (2) from the junction block. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 9598 1. Install the generator cable (2) to the junction block. 2. Install the generator cable nut. Tighten Tighten the nut to 9 N.m (80 lb in). 3. Close the positive cable junction block. 4. Install the generator cable to the generator, perform the following: 4.1. Install the generator cable to the stud. 4.2. Install the generator cable nut. Tighten Tighten the nut to 9 N.m (80 lb in). 4.3. Position the boot to cover the stud. 5. If necessary, install the engine sight shield. 6. Connect the negative battery cable Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 9599 Alternator: Service and Repair Generator Bracket Replacement - Auxiliary GENERATOR BRACKET REPLACEMENT - AUXILIARY REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Disconnect the auxiliary generator electrical connector (3). 3. Remove the drive belt. 4. Remove the positive cable from the auxiliary generator, perform the following: 4.1. Slide the boot (4) down to access the terminal stud. 4.2. Remove the positive cable nut (1). 4.3. Remove the positive cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 9600 5. Remove the auxiliary generator bolts (3). 6. Remove the auxiliary generator (4). 7. Remove the auxiliary generator bracket bolt. 8. Remove the auxiliary generator bracket. INSTALLATION PROCEDURE 1. Install the auxiliary generator bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 9601 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the auxiliary generator bracket bolt. Tighten Tighten the bolt to 50 N.m (37 lb ft). 3. Install the auxiliary generator (4). 4. Install the auxiliary generator bolts (3). Tighten Tighten the bolt to 50 N.m (37 lb ft). 5. Install the positive cable to the auxiliary generator, perform the following: 5.1. Install the positive cable. 5.2. Install the positive cable nut (1). Tighten Tighten the nut to 9 N.m (80 lb in). 5.3. Slide the boot (4) up to cover the terminal stud. 6 Install the drive belt. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 9602 7. Connect the auxiliary generator electrical connector (3). 8. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 9603 Alternator: Service and Repair Generator Replacement GENERATOR REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Disconnect the generator electrical connector (1). 3. Remove the drive belt. 4. Remove the positive battery cable from the generator, perform the following: 4.1. Slide the boot (3) down to access the terminal stud. 4.2. Remove the positive cable nut (2). 4.3. Remove the positive cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 9604 5. Remove the generator bolts (1). 6. Remove the generator (2). INSTALLATION PROCEDURE 1. Install the generator (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the generator bolts (1). Tighten Tighten the bolts to 50 N.m (37 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 9605 3. Install the positive battery cable to the generator, perform the following: 3.1. Install the positive cable. 3.2. Install the positive cable nut (2). Tighten Tighten the nut to 9 N.m (80 lb in). 3.3. Slide the boot (3) up to cover the terminal stud. 4. Install the drive belt. 5. Connect the generator electrical connector (1). 6. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 9606 Alternator: Service and Repair Generator Replacement - Auxiliary GENERATOR REPLACEMENT - AUXILIARY REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Disconnect the auxiliary generator electrical connector (3). 3. Remove the drive belt. 4. Remove the positive cable from the auxiliary generator, perform the following: 4.1. Slide the boot (4) down to access the terminal stud. 4.2. Remove the positive cable nut (1). 4.3. Remove the positive cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 9607 5. Remove the auxiliary generator bolts (3). 6. Remove the auxiliary generator (4). INSTALLATION PROCEDURE 1. Install the auxiliary generator (4). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the auxiliary generator bolts (3). Tighten Tighten the bolts to 50 N.m (37 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 9608 3. Install the positive cable to the auxiliary generator, perform the following: 3.1. Install the positive cable. 3.2. Install the positive cable nut (1). Tighten Tighten the nut to 9 N.m (80 lb in). 3.3. Slide the boot (4) up to cover the terminal stud. 4. Install the drive belt. 5. Connect the auxiliary generator electrical connector (3). 6. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Description and Operation Voltage Regulator: Description and Operation REGULATOR The voltage regulator controls the field current of the rotor in order to limit system voltage. The regulator switches the current on and off at a rate of 400 cycles per second in order to perform the following functions: Radio noise control - Obtain the correct average current needed for proper system voltage control At high speeds, the on-time may be 10 percent with the off-time at 90 percent. At low speeds, the on-time may be 90 percent and the off-time 10 percent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Diagrams Clutch Start Switch (M/T) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 9620 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 9621 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 9622 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Heat Shield > Component Information > Service and Repair Starter Heat Shield: Service and Repair STARTER SHIELD REPLACEMENT REMOVAL PROCEDURE 1. Remove the starter motor. 2. If equipped with a 4.8L, 5.3L, or 6.0L engine, remove the starter heat shield. 3. If equipped with a 8.1L engine, remove the starter heat shield bolts, and nut. 4. Remove the starter heat shield. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Heat Shield > Component Information > Service and Repair > Page 9627 1. If equipped with a 8.1L engine, install the starter heat shield. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the starter heat shield bolts, and nut. Tighten Tighten the bolts to 3 N.m (35 lb in). - Tighten the nut to 5 N.m (44 lb in). 1. If equipped with a 4.8L, 5.3L, or 6.0L engine, install the starter heat shield. 2. Install the starter motor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Locations Starter Solenoid: Locations Starter Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Locations > Page 9631 Right Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Locations > Page 9632 Lower Right Side Of The Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Below Rear Seat (HP2) Below Rear Seat (HP2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Below Rear Seat (HP2) > Page 9638 Lower Center Of The I/P Components Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Below Rear Seat (HP2) > Page 9639 Multifunction Accessory Switch (HP2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Below Rear Seat (HP2) > Page 9640 Right Rear Corner of Bed (HP2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9643 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9644 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9645 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9646 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9647 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9648 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9649 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9650 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9651 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9652 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9653 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9654 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9655 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9656 Auxiliary Power Outlet: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9657 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9658 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9659 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9660 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9661 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9662 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9663 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9664 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9665 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9666 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9667 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9668 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9669 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9670 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9671 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9672 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9673 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9674 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9675 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9676 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9677 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9678 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9679 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9680 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9681 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9682 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9683 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9684 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9685 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9686 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9687 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9688 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9689 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9690 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9691 Auxiliary Power Outlet: Connector Views Auxiliary Power Outlet - Bin (With RPO Code Y91) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9692 Auxiliary Power Outlet - Console (With RPO Code UQ7) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9693 Auxiliary Power Outlet - Front (Except Z75) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9694 Auxiliary Power Outlet Switch (With RPO Code HP2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9695 Auxiliary Power Outlet 120-Volt AC - Exterior (With RPO Code HP2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9696 Auxiliary Power Outlet 120-Volt AC - Interior (With RPO Code HP2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9697 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Auxiliary Outlets Diagram 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9698 Cigar Lighter/Auxiliary Outlets Diagram 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9699 Cigar Lighter/Auxiliary Outlets Diagram 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9700 Cigar Lighter/Auxiliary Outlets Diagram 4 (1 Of 2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 9701 Cigar Lighter/Auxiliary Outlets Diagram 4 (2 Of 2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 9702 Auxiliary Power Outlet: Description and Operation POWER OUTLETS - DESCRIPTION AND OPERATION The 120-volt auxiliary power outlets (APO) are located in the cab and within the pickup bed. The APOs provide 120 volts A/C at 60 hertz with a total a total circuit current of 20 amps. All of the APOs are protected by a ground fault detector located in the starter generator control module (SGCM). The ground fault detector will turn OFF all the outlets if a short to ground is detected or a current overload of greater than 20 amps occurs. After correcting the APOs circuit fault, the APO momentary push button switch on the instrument panel (I/P) may be pressed to reset the ground fault detector. The 120-volt APOs are activated with a momentary push button that located on the I/P. There are 3 states displayed by the 120-volt APO switch indicator lamp. If the lamp is illuminated, then the APOs circuit is activated and the vehicle is in the normal mode. A flashing indicator lamp signals that the system is in the continuous mode. If the indicator is OFF, the 120-volt A/C APOs are OFF. For more information on the hybrid system, review the following Description and Operations. - Energy Storage Box (ESB) Description and Operation in Starting and Charging - Hybrid Control Module (HCM) Description and Operation in Starting and Charging - Starter/Generator Description and Operation in Starting and Charging - Starter/Generator Control Module (SGCM) Description and Operation in Starting and Charging Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Auxiliary Power Outlet: Initial Inspection and Diagnostic Overview Diagnostic Starting Point DIAGNOSTIC STARTING POINT - POWER OUTLETS Begin the system diagnosis with the Diagnostic System Check - Power Outlets. The Diagnostic System Check will provide the following information: - The identification of the control module(s) which command the system. - The ability of the control modules to communicate through the serial data circuit. - The identification of any stored diagnostic trouble codes (DTCs) and their status. The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check - Power Outlets DIAGNOSTIC SYSTEM CHECK - POWER OUTLETS TEST DESCRIPTION Steps 1-2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9705 Steps 3-4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9706 Steps 5-7 The numbers below refer to the step numbers on the diagnostic table. 4. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 5. The symptom list in Symptoms will determine the correct diagnostic procedure to use. 6. The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9707 Auxiliary Power Outlet: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Ignition 1 Signal: The scan tool displays the current voltage at the battery. GEN L-Terminal Signal Command: The scan tool displays OK/No Output. The scan tool displays OK until malfunction is detected on the generator L terminal circuit, then it reads No Output. GEN F-Terminal Signal: The scan tool displays 0-100%. The scan tool displays 0-5% until the engine is running, then the percentage value varies depending on electrical loads. Powertrain Control Module (PCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9708 Hybrid Control Module (HCM) - Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9709 Hybrid Control Module (HCM) - Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9710 Energy Storage Control Module (ESCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9711 Starter/Generator Control Module (SGCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > 120 Volt Receptacle Replacement Auxiliary Power Outlet: Service and Repair 120 Volt Receptacle Replacement 120 VOLT RECEPTACLE REPLACEMENT REMOVAL PROCEDURE 1. Remove the receptacle outlet screws (2). 2. Remove the receptacle outlet (3) from the receptacle box (1). 3. Disconnect the receptacle electrical connections. INSTALLATION PROCEDURE 1. Connect the receptacle electrical connections. 2. Install the receptacle outlet (3) to the receptacle box (1). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the receptacle outlet screws (2). Tighten Tighten the screws to 2 N.m (18 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > 120 Volt Receptacle Replacement > Page 9714 Auxiliary Power Outlet: Service and Repair Accessory Power Receptacle Replacement - 12 Volt ACCESSORY POWER RECEPTACLE REPLACEMENT - 12 VOLT TOOLS REQUIRED J 42059 Cigar Lighter Socket Remover REMOVAL PROCEDURE 1. Remove the power supply fuse. 2. Lift up the front cover of the receptacle. 3. Insert the J 42059 into the receptacle sleeve. Tilt the tool so that the tool fits into the slots on the sides of the receptacle sleeve. 4. Hold the plastic ring in place. Pull the receptacle out of the assembly in order to remove the outlet. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > 120 Volt Receptacle Replacement > Page 9715 5. If J 42059 tool fails to release the power port/lighter socket from the retainer, perform the following alternate method: 5.1. Insert a small grinding tool with a cutoff wheel into the socket. 5.2. Remove the plastic latches in the 3 mm (0.11 in) square windows. 5.3. Use the J 42059 as directed above to remove the socket. 6. Remove the electrical connector from the socket. INSTALLATION PROCEDURE 1. Insert the plastic ring into the opening and snap the plastic ring into place. 2. Connect the electrical connector to the receptacle. 3. Insert the receptacle through the plastic ring gently by hand until the receptacle ring is sealed. 4. Install the power supply fuse. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Page 9716 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-49-018A > May > 06 > Instruments - Service Tire Monitor Message is Displayed Fuse: Customer Interest Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-46-005 > Dec > 04 > OnStar(R) - System Inoperative/No LED Lamp ON Fuse: Customer Interest OnStar(R) - System Inoperative/No LED Lamp ON Bulletin No.: 04-08-46-005 Date: December 21, 2004 TECHNICAL Subject: OnStar(R) Generation 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models: 2004-2005 Buick Rainier, Rendezvous 2005 Buick Allure (Canada), LaCrosse, LeSabre, Terrazza 2004-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2005 Cadillac CTS, DeVille 2004-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2005 Chevrolet Colorado, Express, Impala, Monte Carlo, Uplander 2004-2005 GMC Denali, Denali XL, Envoy, Envoy XL, Envoy XUV, Sierra, Yukon, Yukon XL 2005 GMC Canyon, Savana 2004-2005 Pontiac Aztek 2005 Pontiac Bonneville, Grand Prix, Montana SV6, Vibe with Digital Gen 6 OnStar(R) (RPO UE1) Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module VCIM) with a Tech 2(R). Correction Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, you will need to replace the VCIM. If the VCIM is not replaced, there is the possibility that the customer will return to the dealership with the same conditions at a later date. Please contact the GM Technical Assistance Center (TAC), to obtain a new VCIM. The TAC consultant will verify your diagnosis and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a significant non-return core charge. After the VCIM has been replaced, press the blue OnStar(R) button and request a full reconfiguration. When contacting TAC regarding this concern, the availability of certain information from the vehicle will streamline the process for the dealership technician as well as minimize the time necessary for TAC to provide the correct diagnosis. Please refer to Corporate Bulletin Number 01-00-89-011B for further information concerning the information necessary before contacting TAC. Dealers in Canada should refer to GM Service Policies & Procedures Section 5.3.1 "DEALER REQUIREMENTS FOR ASSISTANCE". Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-46-005 > Dec > 04 > OnStar(R) - System Inoperative/No LED Lamp ON > Page 9729 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 07-08-45-002 > Sep > 07 > Electrical - Aftermarket Fuse Warning Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 05-08-49-018A > May > 06 > Instruments - Service Tire Monitor Message is Displayed Fuse: All Technical Service Bulletins Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 04-08-46-005 > Dec > 04 > OnStar(R) - System Inoperative/No LED Lamp ON Fuse: All Technical Service Bulletins OnStar(R) - System Inoperative/No LED Lamp ON Bulletin No.: 04-08-46-005 Date: December 21, 2004 TECHNICAL Subject: OnStar(R) Generation 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models: 2004-2005 Buick Rainier, Rendezvous 2005 Buick Allure (Canada), LaCrosse, LeSabre, Terrazza 2004-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2005 Cadillac CTS, DeVille 2004-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2005 Chevrolet Colorado, Express, Impala, Monte Carlo, Uplander 2004-2005 GMC Denali, Denali XL, Envoy, Envoy XL, Envoy XUV, Sierra, Yukon, Yukon XL 2005 GMC Canyon, Savana 2004-2005 Pontiac Aztek 2005 Pontiac Bonneville, Grand Prix, Montana SV6, Vibe with Digital Gen 6 OnStar(R) (RPO UE1) Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module VCIM) with a Tech 2(R). Correction Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, you will need to replace the VCIM. If the VCIM is not replaced, there is the possibility that the customer will return to the dealership with the same conditions at a later date. Please contact the GM Technical Assistance Center (TAC), to obtain a new VCIM. The TAC consultant will verify your diagnosis and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a significant non-return core charge. After the VCIM has been replaced, press the blue OnStar(R) button and request a full reconfiguration. When contacting TAC regarding this concern, the availability of certain information from the vehicle will streamline the process for the dealership technician as well as minimize the time necessary for TAC to provide the correct diagnosis. Please refer to Corporate Bulletin Number 01-00-89-011B for further information concerning the information necessary before contacting TAC. Dealers in Canada should refer to GM Service Policies & Procedures Section 5.3.1 "DEALER REQUIREMENTS FOR ASSISTANCE". Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 04-08-46-005 > Dec > 04 > OnStar(R) - System Inoperative/No LED Lamp ON > Page 9743 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuse: > 07-08-45-002 > Sep > 07 > Electrical - Aftermarket Fuse Warning Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Underhood Fuse Block LR Of The Engine Compartment (With RPO Code 9L4) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Underhood Fuse Block > Page 9751 Fuse: Locations I/P Fuse Block Body Control Module (BCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Underhood Fuse Block > Page 9752 Body Harness Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary Fuse: Application and ID Fuse Block - Underhood - Secondary Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 9755 Application Table Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 9756 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 9757 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 9758 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 9759 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 9760 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 9761 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 9762 Fuse: Application and ID Fuse Block - I/P Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 9763 Application Tabel Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 9764 Application Tabel Part 2 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 9765 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 9766 Fuse: Application and ID Fuse Block - Underhood Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 9767 Application Table Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 9768 Application Table Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 9769 Application Table Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 9770 Application Table Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 9771 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 9772 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 9773 Fuse: Application and ID Junction Block - I/P Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 9774 Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 9775 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 9776 Junction Block - I/P Wire Entry Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 9777 Junction Block - I/P Wire Entry Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 9778 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Instrument Panel (IP) Fuse Block: Locations Fuse Block - Instrument Panel (IP) Body Harness Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Instrument Panel (IP) > Page 9783 Body Control Module (BCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Instrument Panel (IP) > Page 9784 LR Of The Engine Compartment (With RPO Code 9L4) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Fuse Block - I/P C4 (Crew Cab) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9787 Fuse Block - Underhood C1 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9788 Fuse Block - Underhood C1 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9789 Fuse Block - Underhood C1 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9790 Fuse Block - Underhood C1 Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9791 Fuse Block - Underhood C1 Part 5 Fuse Block - Underhood C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9792 Fuse Block - Underhood C2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9793 Fuse Block - Underhood C2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9794 Fuse Block - Underhood C2 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9795 Fuse Block - Underhood C2 Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9796 Fuse Block - Underhood C2 Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9797 Fuse Block - Underhood C2 Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9798 Fuse Block - Underhood C3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9799 Fuse Block - Underhood C3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9800 Fuse Block - Underhood C3 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9801 Fuse Block - Underhood C4 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9802 Fuse Block - Underhood C4 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9803 Fuse Block - Underhood C4 Part 3 Fuse Block - Underhood C5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9804 Fuse Block - Underhood C6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9805 Fuse Block - Underhood C7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9806 Fuse Block - Underhood C9 Fuse Block- I/P C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9807 Fuse Block- I/P C1 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9808 Fuse Block- I/P C1 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9809 Fuse Block- I/P C1 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9810 Fuse Block- I/P C1 Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9811 Fuse Block- I/P C1 Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9812 Fuse Block- I/P C1 Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9813 Fuse Block- I/P C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9814 Fuse Block- I/P C3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9815 Fuse Block- I/P C3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9816 Fuse Block- I/P C3 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9817 Junction Block - I/P - C2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9818 Junction Block - I/P - C2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9819 Junction Block - I/P - C4 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9820 Junction Block - I/P - C4 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9821 Junction Block - I/P - C5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9822 Junction Block - I/P - C6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9823 Junction Block - I/P - C7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9824 Junction Block - I/P - C8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9825 Junction Block - Rear Lamps - C1 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9826 Junction Block - Rear Lamps - C1 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9827 Junction Block - Rear Lamps - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9828 Junction Block - Rear Lamps - C3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9829 Junction Block - Rear Lamps - C4 Relay Block - I/P C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9830 Relay Block - I/P C1 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9831 Relay Block - I/P C1 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9832 Relay Block - I/P C1 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9833 Relay Block - I/P C1 Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9834 Relay Block - I/P C1 Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9835 Relay Block - I/P C1 Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9836 Relay Block - I/P C1 Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9837 Relay Block - I/P C3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9838 Relay Block - I/P C3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9839 Relay Block - I/P C4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9840 Relay Block - I/P C5 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9841 Relay Block - I/P C5 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9842 Relay Block - I/P C8 (With RPO Codes 5G4/5X7/5Y0/TRW) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9843 Relay Block - I/P C9 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9844 Relay Block - I/P C9 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9845 Relay Block - I/P C10 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9846 Relay Block - I/P C10 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 9847 Relay Block I/P C7 (With RPO Codes Z82 Or T89) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Fuse Block: Application and ID Fuse Block - I/P Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 9850 Application Tabel Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 9851 Application Tabel Part 2 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 9852 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 9853 Fuse Block: Application and ID Fuse Block - Underhood Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 9854 Application Table Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 9855 Application Table Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 9856 Application Table Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 9857 Application Table Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 9858 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 9859 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 9860 Fuse Block: Application and ID Fuse Block - Underhood - Secondary Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 9861 Application Table Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 9862 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 9863 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 9864 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 9865 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 9866 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 9867 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 9868 Fuse Block: Application and ID Junction Block - I/P Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 9869 Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 9870 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 9871 Junction Block - I/P Wire Entry Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 9872 Junction Block - I/P Wire Entry Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 9873 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9876 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9877 1. Install the engine electrical center bracket assembly to the front fender. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 4 retaining bolts (1). Tighten Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9878 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9879 Fuse Block: Service and Repair I/P Electrical Center or Junction Block Replacement - Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9880 8. Install the left side end panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9881 Fuse Block: Service and Repair I/P Electrical Center or Junction Block Replacement - Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolt. Tighten Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9882 4. Connect the wiring connectors to the fuse block. Refer to Electrical Center Identification Views to ensure the right connections are made. 5. Install the right side end panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9883 Fuse Block: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolts. Tighten Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 9884 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component Information > Service and Repair Ground Strap: Service and Repair GROUND STRAP REPLACEMENT REMOVAL PROCEDURE 1. If necessary, remove the engine sight shield. 2. Remove the engine wiring harness ground bolt. 3. Reposition the engine wiring harness ground and ground strap. 4. Remove the ground strap nut from the stud at the front of dash. 5. Remove the ground strap from the stud. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component Information > Service and Repair > Page 9888 1. Install the ground strap to the stud. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ground strap nut to the stud at the front of dash. Tighten Tighten the nut to 9 N.m (80 lb in). 3. Position the ground strap and engine wiring harness ground. 4. Install the engine wiring harness ground bolt. Tighten Tighten the bolt to 16 N.m (12 lb ft). 5. If necessary, install the engine sight shield. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 9897 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9903 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9904 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9905 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9906 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9907 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9908 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 9913 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9919 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9920 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9921 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9922 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9923 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 9924 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 Multiple Junction Connector: Diagrams C100 - C198 C100 I/P Harness To Engine Harness Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9929 C100 I/P Harness To Engine Harness Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9930 C102 I/P Harness To Chassis Harness Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9931 C102 I/P Harness To Chassis Harness Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9932 C103 I/P Harness To Forward Lamp Harness (Export) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9933 C104 I/P Harness To Forward Lamp Harness (With RPO Code YE9) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9934 C104 I/P Harness To Forward Lamp Harness (With Out RPO Code YE9) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9935 C106 Engine Harness To I/P Harness (With RPO Code PTO) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9936 C107 Main Engine Harness To Engine Jumper Harness Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9937 C107 Main Engine Harness To Engine Jumper Harness Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9938 C107 Main Engine Harness To Engine Jumper Harness Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9939 C108 Main Engine Harness To Engine Jumper Harness Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9940 C108 Main Engine Harness To Engine Jumper Harness Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9941 C108 Main Engine Harness To Engine Jumper Harness Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9942 C113 Engine Jumper Harness To Engine Harness Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9943 C115 Chassis Harness To I/P Harness (With RPO Code NYS) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9944 C115 Chassis Harness To I/P Harness (With RPO Code NYS) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9945 C117 Battery Negative Harness To Accessory Jumper Harness (With RPO Code 9L4) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9946 C119 Accessory Jumper Harness To Brake/Clutch Harness (With RPO Code 9L4) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9947 C125 Snowplow Harness To Forward Lamp Harness (With RPO Code VYU) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9948 C127 Snowplow Harness To Forward Lamp Harness (With RPO Code VYU) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9949 C150 4-Wheel Drive Harness To 4-Wheel Drive Jumper Harness (With RPO Code NP8) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9950 C151 I/P Harness To ATC Harness (With RPO Codes NP1/NP8) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9951 C152 Chassis Harness To Engine Harness Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9952 C152 Chassis Harness To Engine Harness Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9953 C153 4-Wheel Drive Harness To Engine Harness Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9954 C154 I/P Harness To ATC Harness (With RPO Codes NP1/NP8) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9955 C160 Chassis Harness To Brake/Clutch Harness (With RPO Codes 5X7/5Y0) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9956 C161 Roof Beacon Harness To Chassis Harness (With RPO Code 5Y0) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9957 C198 I/P Harness To Chassis Harness Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9958 Multiple Junction Connector: Diagrams C201 - C277 C201 Steering Column Harness To I/P Harness Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9959 C201 Steering Column Harness To I/P Harness Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9960 C201 Steering Column Harness To I/P Harness Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9961 C201 Steering Column Harness To I/P Harness Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9962 C202 I/P Harness To Brake/Clutch Harness Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9963 C202 I/P Harness To Brake/Clutch Harness Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9964 C206 I/P Harness To Body Harness (With RPO Codes Y91/HP2) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9965 C206 I/P Harness To Body Harness (With RPO Codes Y91/HP2) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9966 C210 Brake/Clutch Harness To Beacon Harness (With RPO Codes 5G4/TRW) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9967 C214 I/P Harness To Headliner Harness (With RPO Code U42) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9968 C214 I/P Harness To Headliner Harness (With RPO Code U42) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9969 C214 Infotainment Harness To Headliner Harness (With RPO Code UE1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9970 C216 Brake/Clutch Harness To Fuse Block Jumper Harness (With RPO Code 9L4) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9971 C220 I/P Harness To Infotainment Jumper Harness (With RPO Code UQ7 & Without RPO Code Y91) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9972 C220 I/P Harness To Infotainment Jumper Harness (With RPO Code UQ7 & Without RPO Code Y91) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9973 C221 I/P Harness To Body Harness (With Single Stage Air Bag) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9974 C221 I/P Harness To Body Harness (With Dual Stage Air Bag) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9975 C222 I/P Harness To Body Harness Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9976 C223 I/P Harness To Body Harness (Except NYS And HP2) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9977 C223 I/P Harness To Body Harness (Except NYS And HP2) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9978 C230 I/P Harness (With RPO Codes UE1 And Y91) Or Infotainment Jumper Harness (With RPO Code UE1 & Without RPO Code Y91) To Roofmarker Harness Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9979 C249 I/P Harness To Bezel Harness (Except Y91) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9980 C249 Console Harness To Bezel Harness (With RPO Code Y91) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9981 C250 Brake/Clutch Harness To Brake Clutch Jumper Harness (With RPO Code ZX3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9982 C250 Brake/Clutch Harness To Brake Clutch Jumper Harness (With RPO Codes 5X7, 5G4, 5Y0, And TRW) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9983 C275 Steering Column Harness To Steering Wheel Module Coil (With RPO Code HVY) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9984 C275 Steering Column Harness To Steering Wheel Module Coil (With RPO Code AL0) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9985 C277 Steering Wheel Module Coil To Steering Wheel Harness (With RPO Code UK3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9986 Multiple Junction Connector: Diagrams C305 - C399 C305 Body Harness To Drivers Seat Harness (With RPO Code AG1) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9987 C305 Body Harness To Drivers Seat Harness (With RPO Code AG1) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9988 C306 Infotainment Jumper Harness To Console Harness (Without RPO Code Y91) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9989 C306 Infotainment Jumper Harness To Console Harness (Without RPO Code Y91) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9990 C306 Infotainment Jumper Harness To Console Harness (Without RPO Code Y91) Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9991 C306 Infotainment Jumper Harness To Console Harness (With RPO Code Y91) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9992 C306 Infotainment Jumper Harness To Console Harness (With RPO Code Y91) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9993 C306 Infotainment Jumper Harness To Console Harness (With RPO Code Y91) Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9994 C310 Body Harness To Left Rear Door Harness (Crew Cab) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9995 C310 Body Harness To Left Rear Door Harness (Crew Cab) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9996 C320 Seat Jumper Harness To Seat Harness (With RPO Code AN3) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9997 C320 Seat Jumper Harness To Seat Harness (With RPO Code AN3) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9998 C321 Seat Jumper Harness To Seat Harness (With RPO Code AN3) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 9999 C321 Seat Jumper Harness To Seat Harness (With RPO Code AN3) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10000 C322 Seat Motor Jumper Harness To Seat Jumper Harness (With RPO Code AN3) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10001 C322 Seat Motor Jumper Harness To Seat Jumper Harness (With RPO Code AN3) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10002 C323 Seat Motor Jumper Harness To Seat Jumper Harness (With RPO Code AG1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10003 C324 Lumbar Bolster Harness To Seat Harness (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10004 C325 Heated Seat Jumper Harness To Seat Jumper Harness (With RPO Code KA1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10005 C326 Heated Seat Jumper Harness To Passenger Seat Harness (With RPO Code KA1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10006 C329 Lumbar Bolster Harness To Passenger Seat Harness (With RPO Code AG2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10007 C330 Body Harness To Passenger Seat Harness (With RPO Code AL0) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10008 C388 Seat Motor Jumper Harness To Passenger Seat Harness (With RPO Code AG2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10009 C396 Body Harness To Right Rear Door Harness (Crew Cab) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10010 C396 Body Harness To Right Rear Door Harness (Crew Cab) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10011 C399 Body Harness To Passenger Seat Harness Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10012 C399 Body Harness To Passenger Seat Harness Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10013 Multiple Junction Connector: Diagrams C404 - C411 C404 Left Clearance Lamp Harness To License Lamp Harness (With RPO Codes NYS Or R05) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10014 C405 Right Clearance Lamp Harness To License Lamp Harness (With RPO Codes NYS Or R05) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10015 C410 Right Rear Lamp Harness To Chassis Harness (With RPO Code T79) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10016 C411 Left Rear Lamp Harness To Chassis Harness (With RPO Code T79) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P Relay Box: Locations Junction Block - I/P Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10022 Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10023 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10024 Junction Block - I/P Wire Entry Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10025 Junction Block - I/P Wire Entry Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10026 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10027 Relay Box: Locations Relay Block - I/P Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10028 Application Table Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10029 Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 10030 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 10031 Junction Block - Rear Lamps - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 10032 Junction Block - Rear Lamps - C3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 10033 Junction Block - Rear Lamps - C4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P Relay Box: Application and ID Junction Block - I/P Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10036 Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10037 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10038 Junction Block - I/P Wire Entry Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10039 Junction Block - I/P Wire Entry Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10040 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10041 Relay Box: Application and ID Relay Block - I/P Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10042 Application Table Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10043 Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10046 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10047 1. Install the engine electrical center bracket assembly to the front fender. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 4 retaining bolts (1). Tighten Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10048 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10049 Relay Box: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolts. Tighten Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10050 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10051 Relay Box: Service and Repair I/P Electrical Center or Junction Block Replacement - Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10052 8. Install the left side end panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10053 Relay Box: Service and Repair I/P Electrical Center or Junction Block Replacement - Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolt. Tighten Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10054 4. Connect the wiring connectors to the fuse block. Refer to Electrical Center Identification Views to ensure the right connections are made. 5. Install the right side end panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P Relay Box: Locations Junction Block - I/P Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10059 Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10060 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10061 Junction Block - I/P Wire Entry Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10062 Junction Block - I/P Wire Entry Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10063 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10064 Relay Box: Locations Relay Block - I/P Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10065 Application Table Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10066 Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 10067 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 10068 Junction Block - Rear Lamps - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 10069 Junction Block - Rear Lamps - C3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 10070 Junction Block - Rear Lamps - C4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P Relay Box: Application and ID Junction Block - I/P Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10073 Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10074 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10075 Junction Block - I/P Wire Entry Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10076 Junction Block - I/P Wire Entry Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10077 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10078 Relay Box: Application and ID Relay Block - I/P Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10079 Application Table Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10080 Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10083 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10084 1. Install the engine electrical center bracket assembly to the front fender. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 4 retaining bolts (1). Tighten Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10085 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10086 Relay Box: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolts. Tighten Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10087 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10088 Relay Box: Service and Repair I/P Electrical Center or Junction Block Replacement - Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10089 8. Install the left side end panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10090 Relay Box: Service and Repair I/P Electrical Center or Junction Block Replacement - Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolt. Tighten Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10091 4. Connect the wiring connectors to the fuse block. Refer to Electrical Center Identification Views to ensure the right connections are made. 5. Install the right side end panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10100 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10101 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10102 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-04-034 > Aug > 09 > Fuel System - Reduced Engine Power, MIL (Various Codes) Wiring Harness: Customer Interest Fuel System - Reduced Engine Power, MIL (Various Codes) TECHNICAL Bulletin No.: 09-06-04-034 Date: August 17, 2009 Subject: Malfunction Indicator Lamp (MIL) Illuminated, Fuel Injector Driver Circuit DTCs P0201, P0202, P0203, P0204, P0205, P0206, P0207, P0208 and Cylinder Bank Shut Down DTCs P2146 or P2149, Reduced Engine Power (Repair Fuel Injector Control Module (FICM) Harness Chafed Wires) Models: 2001-2004 Chevrolet Kodiak C4500/C5500 Series, Silverado Models 2001-2004 GMC Sierra Models, TopKick C4500/C5500 Series Equipped with Duramax(TM) Diesel Engine RPO LB7 2004-2005 Chevrolet Kodiak, Silverado Models 2004-2005 GMC Sierra Models, TopKick Equipped with Duramax Diesel Engine RPO LLY Please Refer to GMVIS Condition Some customers may comment that the malfunction indicator lamp (MIL) is illuminated or intermittent and there is a significant reduction in engine power (limp home mode). The scan tool may display one or more Injector Driver Circuit DTCs P0201, P0202, P0203, P0204, P0205, P0206, P0207 or P0208 and/or Cylinder Bank Shut Down DTCs P2146 or P2149 set as Current or in History. Cause This condition may be caused by the fuel injector control module (FICM) wiring harness protective conduit rubbing against the back of the alternator, the alternator bracket or the FICM harness retaining bracket. This may result in the conduit rubbing through, exposing the wires inside and chafing of the wire insulation then occurs. Correction 1. Turn ON the ignition, with the engine OFF. 2. Observe the DTC information with the scan tool. 3. If any of the above DTCs are set, then proceed to inspect the FICM wiring harness at the locations outlined in the following steps. 4. Turn OFF the ignition and all accessories and allow the control modules to power down. Note For Silverado and Sierra models only perform Step 5. 5. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. Important DO NOT break off the tab on the electrical connectors. 6. Disconnect the FICM electrical connectors (2) from the FICM (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-04-034 > Aug > 09 > Fuel System - Reduced Engine Power, MIL (Various Codes) > Page 10107 7. Carefully bend up and backwards the FICM wiring harness electrical connectors (1) away from the FICM (4). Note Some of these chafes are very small, possibly the size of a pen tip, but could still cause injector circuit concerns. 8. Inspect the wiring harness for chafing (3) that may result from rubbing at the back of the alternator (2), the alternator bracket or at the FICM harness retaining bracket. If necessary, peel the tape from the area and look for ANY chafes into the wires. ^ If chafing is observed and the conductive portion of the wire IS NOT damaged, apply electrical tape around the wire. ^ If chafing is observed and the conductive portion of the wire IS damaged, then refer to Splicing Copper Wire Using Splice Sleeves in Wiring Repairs in SI. ^ If chafing IS NOT OBSERVED, then refer to the appropriate DTC Diagnostic procedures in SI. 9. Connect the electrical connectors to the FICM. 10. Insulate the harness with suitable material such as conduit or heater hose to prevent a reoccurrence. Note For Silverado and Sierra models only perform Step 11. 11. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 12. Clear the DTCs with a scan tool. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-50-014A > Jan > 06 > Electrical - No Module Communication/DTCs/Warning Lamps Wiring Harness: Customer Interest Electrical - No Module Communication/DTCs/Warning Lamps Bulletin No.: 03-08-50-014A Date: January 20, 2006 TECHNICAL Subject: No Communication with Any Modules, Memory Seat May Not Recall, Multiple U-DTCs Set or Instrument Panel Cluster (IPC) Warning Indicators, Crank No Start (Inspect/Repair Affected Wiring Harness) Models: 2003-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL with Front, Individual (Non-Bkt) Seat (RPO AN3) and/or Active Brake Control (Stabilitrak(R)) (RPO JL4) Supercede: This bulletin is being revised to update the various conditions and add the 2004-2006 model years, additional diagnostic and warranty information. Please discard Corporate Bulletin Number 03-08-50-014 (Section 08 - Body & Accessories). Condition Some customers may comment on any of the following conditions: ^ Various IPC Warning indicators are coming on. ^ Driver Information Center (DIC) displays "Unknown Driver". ^ Memory seat may not recall. ^ RKE fobs may be inoperative. ^ Radio or HVAC may shut off. ^ Engine cranks but will not start. Upon investigation, the Technician may find multiple U-DTCs set. Cause On RPO AN3 equipped vehicles, a chafed or pinched seat wiring harness under the driver seat may be a cause of this condition. Because of the routing, a portion of the seat wiring harness may rest on the inboard edge of the seat track or frame. Over time, the harness may be pinched or chafed because of the seat movement. Refer to the above illustration. The illustration shows the inverted position of the seat bottom. The arrow shows the primary location Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-50-014A > Jan > 06 > Electrical - No Module Communication/DTCs/Warning Lamps > Page 10112 of the possible harness chafing/pinching. Also, on any of the above listed vehicles, the PCM wiring harness may be chafing against the precharge pump bracket or the battery tray. Correction On RPO AN3 vehicles, inspect the routing of the seat wiring harness. Reroute the seat wiring harness and attaching harness fastener (1) to the opposite side of the seat module bracket. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. The seat may have to be removed for ease of access and proper repair of the wiring harness. Inspect the routing of the PCM wiring harness at the precharge pump bracket and the battery tray. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. If any of the above conditions still remain after this repair, refer to SI for further diagnostic information. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10118 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10119 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10120 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10125 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10126 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10127 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10128 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10129 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10130 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-04-034 > Aug > 09 > Fuel System - Reduced Engine Power, MIL (Various Codes) Wiring Harness: All Technical Service Bulletins Fuel System - Reduced Engine Power, MIL (Various Codes) TECHNICAL Bulletin No.: 09-06-04-034 Date: August 17, 2009 Subject: Malfunction Indicator Lamp (MIL) Illuminated, Fuel Injector Driver Circuit DTCs P0201, P0202, P0203, P0204, P0205, P0206, P0207, P0208 and Cylinder Bank Shut Down DTCs P2146 or P2149, Reduced Engine Power (Repair Fuel Injector Control Module (FICM) Harness Chafed Wires) Models: 2001-2004 Chevrolet Kodiak C4500/C5500 Series, Silverado Models 2001-2004 GMC Sierra Models, TopKick C4500/C5500 Series Equipped with Duramax(TM) Diesel Engine RPO LB7 2004-2005 Chevrolet Kodiak, Silverado Models 2004-2005 GMC Sierra Models, TopKick Equipped with Duramax Diesel Engine RPO LLY Please Refer to GMVIS Condition Some customers may comment that the malfunction indicator lamp (MIL) is illuminated or intermittent and there is a significant reduction in engine power (limp home mode). The scan tool may display one or more Injector Driver Circuit DTCs P0201, P0202, P0203, P0204, P0205, P0206, P0207 or P0208 and/or Cylinder Bank Shut Down DTCs P2146 or P2149 set as Current or in History. Cause This condition may be caused by the fuel injector control module (FICM) wiring harness protective conduit rubbing against the back of the alternator, the alternator bracket or the FICM harness retaining bracket. This may result in the conduit rubbing through, exposing the wires inside and chafing of the wire insulation then occurs. Correction 1. Turn ON the ignition, with the engine OFF. 2. Observe the DTC information with the scan tool. 3. If any of the above DTCs are set, then proceed to inspect the FICM wiring harness at the locations outlined in the following steps. 4. Turn OFF the ignition and all accessories and allow the control modules to power down. Note For Silverado and Sierra models only perform Step 5. 5. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. Important DO NOT break off the tab on the electrical connectors. 6. Disconnect the FICM electrical connectors (2) from the FICM (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-04-034 > Aug > 09 > Fuel System - Reduced Engine Power, MIL (Various Codes) > Page 10135 7. Carefully bend up and backwards the FICM wiring harness electrical connectors (1) away from the FICM (4). Note Some of these chafes are very small, possibly the size of a pen tip, but could still cause injector circuit concerns. 8. Inspect the wiring harness for chafing (3) that may result from rubbing at the back of the alternator (2), the alternator bracket or at the FICM harness retaining bracket. If necessary, peel the tape from the area and look for ANY chafes into the wires. ^ If chafing is observed and the conductive portion of the wire IS NOT damaged, apply electrical tape around the wire. ^ If chafing is observed and the conductive portion of the wire IS damaged, then refer to Splicing Copper Wire Using Splice Sleeves in Wiring Repairs in SI. ^ If chafing IS NOT OBSERVED, then refer to the appropriate DTC Diagnostic procedures in SI. 9. Connect the electrical connectors to the FICM. 10. Insulate the harness with suitable material such as conduit or heater hose to prevent a reoccurrence. Note For Silverado and Sierra models only perform Step 11. 11. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 12. Clear the DTCs with a scan tool. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 10140 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 03-08-50-014A > Jan > 06 > Electrical - No Module Communication/DTCs/Warning Lamps Wiring Harness: All Technical Service Bulletins Electrical - No Module Communication/DTCs/Warning Lamps Bulletin No.: 03-08-50-014A Date: January 20, 2006 TECHNICAL Subject: No Communication with Any Modules, Memory Seat May Not Recall, Multiple U-DTCs Set or Instrument Panel Cluster (IPC) Warning Indicators, Crank No Start (Inspect/Repair Affected Wiring Harness) Models: 2003-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL with Front, Individual (Non-Bkt) Seat (RPO AN3) and/or Active Brake Control (Stabilitrak(R)) (RPO JL4) Supercede: This bulletin is being revised to update the various conditions and add the 2004-2006 model years, additional diagnostic and warranty information. Please discard Corporate Bulletin Number 03-08-50-014 (Section 08 - Body & Accessories). Condition Some customers may comment on any of the following conditions: ^ Various IPC Warning indicators are coming on. ^ Driver Information Center (DIC) displays "Unknown Driver". ^ Memory seat may not recall. ^ RKE fobs may be inoperative. ^ Radio or HVAC may shut off. ^ Engine cranks but will not start. Upon investigation, the Technician may find multiple U-DTCs set. Cause On RPO AN3 equipped vehicles, a chafed or pinched seat wiring harness under the driver seat may be a cause of this condition. Because of the routing, a portion of the seat wiring harness may rest on the inboard edge of the seat track or frame. Over time, the harness may be pinched or chafed because of the seat movement. Refer to the above illustration. The illustration shows the inverted position of the seat bottom. The arrow shows the primary location Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 03-08-50-014A > Jan > 06 > Electrical - No Module Communication/DTCs/Warning Lamps > Page 10145 of the possible harness chafing/pinching. Also, on any of the above listed vehicles, the PCM wiring harness may be chafing against the precharge pump bracket or the battery tray. Correction On RPO AN3 vehicles, inspect the routing of the seat wiring harness. Reroute the seat wiring harness and attaching harness fastener (1) to the opposite side of the seat module bracket. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. The seat may have to be removed for ease of access and proper repair of the wiring harness. Inspect the routing of the PCM wiring harness at the precharge pump bracket and the battery tray. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. If any of the above conditions still remain after this repair, refer to SI for further diagnostic information. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10151 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10152 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10153 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10154 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10155 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10156 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 10161 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Below Rear Seat (HP2) Below Rear Seat (HP2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Below Rear Seat (HP2) > Page 10167 Lower Center Of The I/P Components Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Below Rear Seat (HP2) > Page 10168 Multifunction Accessory Switch (HP2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Below Rear Seat (HP2) > Page 10169 Right Rear Corner of Bed (HP2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10172 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10173 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10174 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10175 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10176 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10177 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10178 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10179 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10180 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10181 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10182 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10183 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10184 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10185 Auxiliary Power Outlet: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10186 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10187 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10188 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10189 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10190 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10191 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10192 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10193 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10194 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10195 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10196 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10197 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10198 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10199 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10200 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10201 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10202 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10203 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10204 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10205 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10206 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10207 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10208 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10209 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10210 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10211 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10212 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10213 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10214 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10215 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10216 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10217 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10218 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10219 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10220 Auxiliary Power Outlet: Connector Views Auxiliary Power Outlet - Bin (With RPO Code Y91) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10221 Auxiliary Power Outlet - Console (With RPO Code UQ7) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10222 Auxiliary Power Outlet - Front (Except Z75) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10223 Auxiliary Power Outlet Switch (With RPO Code HP2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10224 Auxiliary Power Outlet 120-Volt AC - Exterior (With RPO Code HP2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10225 Auxiliary Power Outlet 120-Volt AC - Interior (With RPO Code HP2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10226 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Auxiliary Outlets Diagram 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10227 Cigar Lighter/Auxiliary Outlets Diagram 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10228 Cigar Lighter/Auxiliary Outlets Diagram 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10229 Cigar Lighter/Auxiliary Outlets Diagram 4 (1 Of 2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10230 Cigar Lighter/Auxiliary Outlets Diagram 4 (2 Of 2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 10231 Auxiliary Power Outlet: Description and Operation POWER OUTLETS - DESCRIPTION AND OPERATION The 120-volt auxiliary power outlets (APO) are located in the cab and within the pickup bed. The APOs provide 120 volts A/C at 60 hertz with a total a total circuit current of 20 amps. All of the APOs are protected by a ground fault detector located in the starter generator control module (SGCM). The ground fault detector will turn OFF all the outlets if a short to ground is detected or a current overload of greater than 20 amps occurs. After correcting the APOs circuit fault, the APO momentary push button switch on the instrument panel (I/P) may be pressed to reset the ground fault detector. The 120-volt APOs are activated with a momentary push button that located on the I/P. There are 3 states displayed by the 120-volt APO switch indicator lamp. If the lamp is illuminated, then the APOs circuit is activated and the vehicle is in the normal mode. A flashing indicator lamp signals that the system is in the continuous mode. If the indicator is OFF, the 120-volt A/C APOs are OFF. For more information on the hybrid system, review the following Description and Operations. - Energy Storage Box (ESB) Description and Operation in Starting and Charging - Hybrid Control Module (HCM) Description and Operation in Starting and Charging - Starter/Generator Description and Operation in Starting and Charging - Starter/Generator Control Module (SGCM) Description and Operation in Starting and Charging Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Auxiliary Power Outlet: Initial Inspection and Diagnostic Overview Diagnostic Starting Point DIAGNOSTIC STARTING POINT - POWER OUTLETS Begin the system diagnosis with the Diagnostic System Check - Power Outlets. The Diagnostic System Check will provide the following information: - The identification of the control module(s) which command the system. - The ability of the control modules to communicate through the serial data circuit. - The identification of any stored diagnostic trouble codes (DTCs) and their status. The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check - Power Outlets DIAGNOSTIC SYSTEM CHECK - POWER OUTLETS TEST DESCRIPTION Steps 1-2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10234 Steps 3-4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10235 Steps 5-7 The numbers below refer to the step numbers on the diagnostic table. 4. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 5. The symptom list in Symptoms will determine the correct diagnostic procedure to use. 6. The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10236 Auxiliary Power Outlet: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Ignition 1 Signal: The scan tool displays the current voltage at the battery. GEN L-Terminal Signal Command: The scan tool displays OK/No Output. The scan tool displays OK until malfunction is detected on the generator L terminal circuit, then it reads No Output. GEN F-Terminal Signal: The scan tool displays 0-100%. The scan tool displays 0-5% until the engine is running, then the percentage value varies depending on electrical loads. Powertrain Control Module (PCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10237 Hybrid Control Module (HCM) - Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10238 Hybrid Control Module (HCM) - Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10239 Energy Storage Control Module (ESCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10240 Starter/Generator Control Module (SGCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > 120 Volt Receptacle Replacement Auxiliary Power Outlet: Service and Repair 120 Volt Receptacle Replacement 120 VOLT RECEPTACLE REPLACEMENT REMOVAL PROCEDURE 1. Remove the receptacle outlet screws (2). 2. Remove the receptacle outlet (3) from the receptacle box (1). 3. Disconnect the receptacle electrical connections. INSTALLATION PROCEDURE 1. Connect the receptacle electrical connections. 2. Install the receptacle outlet (3) to the receptacle box (1). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the receptacle outlet screws (2). Tighten Tighten the screws to 2 N.m (18 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > 120 Volt Receptacle Replacement > Page 10243 Auxiliary Power Outlet: Service and Repair Accessory Power Receptacle Replacement - 12 Volt ACCESSORY POWER RECEPTACLE REPLACEMENT - 12 VOLT TOOLS REQUIRED J 42059 Cigar Lighter Socket Remover REMOVAL PROCEDURE 1. Remove the power supply fuse. 2. Lift up the front cover of the receptacle. 3. Insert the J 42059 into the receptacle sleeve. Tilt the tool so that the tool fits into the slots on the sides of the receptacle sleeve. 4. Hold the plastic ring in place. Pull the receptacle out of the assembly in order to remove the outlet. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > 120 Volt Receptacle Replacement > Page 10244 5. If J 42059 tool fails to release the power port/lighter socket from the retainer, perform the following alternate method: 5.1. Insert a small grinding tool with a cutoff wheel into the socket. 5.2. Remove the plastic latches in the 3 mm (0.11 in) square windows. 5.3. Use the J 42059 as directed above to remove the socket. 6. Remove the electrical connector from the socket. INSTALLATION PROCEDURE 1. Insert the plastic ring into the opening and snap the plastic ring into place. 2. Connect the electrical connector to the receptacle. 3. Insert the receptacle through the plastic ring gently by hand until the receptacle ring is sealed. 4. Install the power supply fuse. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Page 10245 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-49-018A > May > 06 > Instruments - Service Tire Monitor Message is Displayed Fuse: Customer Interest Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-46-005 > Dec > 04 > OnStar(R) - System Inoperative/No LED Lamp ON Fuse: Customer Interest OnStar(R) - System Inoperative/No LED Lamp ON Bulletin No.: 04-08-46-005 Date: December 21, 2004 TECHNICAL Subject: OnStar(R) Generation 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models: 2004-2005 Buick Rainier, Rendezvous 2005 Buick Allure (Canada), LaCrosse, LeSabre, Terrazza 2004-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2005 Cadillac CTS, DeVille 2004-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2005 Chevrolet Colorado, Express, Impala, Monte Carlo, Uplander 2004-2005 GMC Denali, Denali XL, Envoy, Envoy XL, Envoy XUV, Sierra, Yukon, Yukon XL 2005 GMC Canyon, Savana 2004-2005 Pontiac Aztek 2005 Pontiac Bonneville, Grand Prix, Montana SV6, Vibe with Digital Gen 6 OnStar(R) (RPO UE1) Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module VCIM) with a Tech 2(R). Correction Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, you will need to replace the VCIM. If the VCIM is not replaced, there is the possibility that the customer will return to the dealership with the same conditions at a later date. Please contact the GM Technical Assistance Center (TAC), to obtain a new VCIM. The TAC consultant will verify your diagnosis and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a significant non-return core charge. After the VCIM has been replaced, press the blue OnStar(R) button and request a full reconfiguration. When contacting TAC regarding this concern, the availability of certain information from the vehicle will streamline the process for the dealership technician as well as minimize the time necessary for TAC to provide the correct diagnosis. Please refer to Corporate Bulletin Number 01-00-89-011B for further information concerning the information necessary before contacting TAC. Dealers in Canada should refer to GM Service Policies & Procedures Section 5.3.1 "DEALER REQUIREMENTS FOR ASSISTANCE". Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-46-005 > Dec > 04 > OnStar(R) - System Inoperative/No LED Lamp ON > Page 10258 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 07-08-45-002 > Sep > 07 > Electrical - Aftermarket Fuse Warning Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 05-08-49-018A > May > 06 > Instruments - Service Tire Monitor Message is Displayed Fuse: All Technical Service Bulletins Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 04-08-46-005 > Dec > 04 > OnStar(R) - System Inoperative/No LED Lamp ON Fuse: All Technical Service Bulletins OnStar(R) - System Inoperative/No LED Lamp ON Bulletin No.: 04-08-46-005 Date: December 21, 2004 TECHNICAL Subject: OnStar(R) Generation 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models: 2004-2005 Buick Rainier, Rendezvous 2005 Buick Allure (Canada), LaCrosse, LeSabre, Terrazza 2004-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2005 Cadillac CTS, DeVille 2004-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2005 Chevrolet Colorado, Express, Impala, Monte Carlo, Uplander 2004-2005 GMC Denali, Denali XL, Envoy, Envoy XL, Envoy XUV, Sierra, Yukon, Yukon XL 2005 GMC Canyon, Savana 2004-2005 Pontiac Aztek 2005 Pontiac Bonneville, Grand Prix, Montana SV6, Vibe with Digital Gen 6 OnStar(R) (RPO UE1) Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module VCIM) with a Tech 2(R). Correction Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, you will need to replace the VCIM. If the VCIM is not replaced, there is the possibility that the customer will return to the dealership with the same conditions at a later date. Please contact the GM Technical Assistance Center (TAC), to obtain a new VCIM. The TAC consultant will verify your diagnosis and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a significant non-return core charge. After the VCIM has been replaced, press the blue OnStar(R) button and request a full reconfiguration. When contacting TAC regarding this concern, the availability of certain information from the vehicle will streamline the process for the dealership technician as well as minimize the time necessary for TAC to provide the correct diagnosis. Please refer to Corporate Bulletin Number 01-00-89-011B for further information concerning the information necessary before contacting TAC. Dealers in Canada should refer to GM Service Policies & Procedures Section 5.3.1 "DEALER REQUIREMENTS FOR ASSISTANCE". Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 04-08-46-005 > Dec > 04 > OnStar(R) - System Inoperative/No LED Lamp ON > Page 10272 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuse: > 07-08-45-002 > Sep > 07 > Electrical - Aftermarket Fuse Warning Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Underhood Fuse Block LR Of The Engine Compartment (With RPO Code 9L4) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Underhood Fuse Block > Page 10280 Fuse: Locations I/P Fuse Block Body Control Module (BCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Underhood Fuse Block > Page 10281 Body Harness Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary Fuse: Application and ID Fuse Block - Underhood - Secondary Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 10284 Application Table Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 10285 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 10286 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 10287 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 10288 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 10289 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 10290 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 10291 Fuse: Application and ID Fuse Block - I/P Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 10292 Application Tabel Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 10293 Application Tabel Part 2 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 10294 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 10295 Fuse: Application and ID Fuse Block - Underhood Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 10296 Application Table Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 10297 Application Table Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 10298 Application Table Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 10299 Application Table Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 10300 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 10301 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 10302 Fuse: Application and ID Junction Block - I/P Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 10303 Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 10304 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 10305 Junction Block - I/P Wire Entry Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 10306 Junction Block - I/P Wire Entry Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood - Secondary > Page 10307 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Instrument Panel (IP) Fuse Block: Locations Fuse Block - Instrument Panel (IP) Body Harness Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Instrument Panel (IP) > Page 10312 Body Control Module (BCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - Instrument Panel (IP) > Page 10313 LR Of The Engine Compartment (With RPO Code 9L4) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Fuse Block - I/P C4 (Crew Cab) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10316 Fuse Block - Underhood C1 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10317 Fuse Block - Underhood C1 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10318 Fuse Block - Underhood C1 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10319 Fuse Block - Underhood C1 Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10320 Fuse Block - Underhood C1 Part 5 Fuse Block - Underhood C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10321 Fuse Block - Underhood C2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10322 Fuse Block - Underhood C2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10323 Fuse Block - Underhood C2 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10324 Fuse Block - Underhood C2 Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10325 Fuse Block - Underhood C2 Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10326 Fuse Block - Underhood C2 Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10327 Fuse Block - Underhood C3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10328 Fuse Block - Underhood C3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10329 Fuse Block - Underhood C3 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10330 Fuse Block - Underhood C4 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10331 Fuse Block - Underhood C4 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10332 Fuse Block - Underhood C4 Part 3 Fuse Block - Underhood C5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10333 Fuse Block - Underhood C6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10334 Fuse Block - Underhood C7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10335 Fuse Block - Underhood C9 Fuse Block- I/P C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10336 Fuse Block- I/P C1 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10337 Fuse Block- I/P C1 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10338 Fuse Block- I/P C1 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10339 Fuse Block- I/P C1 Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10340 Fuse Block- I/P C1 Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10341 Fuse Block- I/P C1 Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10342 Fuse Block- I/P C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10343 Fuse Block- I/P C3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10344 Fuse Block- I/P C3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10345 Fuse Block- I/P C3 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10346 Junction Block - I/P - C2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10347 Junction Block - I/P - C2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10348 Junction Block - I/P - C4 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10349 Junction Block - I/P - C4 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10350 Junction Block - I/P - C5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10351 Junction Block - I/P - C6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10352 Junction Block - I/P - C7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10353 Junction Block - I/P - C8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10354 Junction Block - Rear Lamps - C1 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10355 Junction Block - Rear Lamps - C1 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10356 Junction Block - Rear Lamps - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10357 Junction Block - Rear Lamps - C3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10358 Junction Block - Rear Lamps - C4 Relay Block - I/P C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10359 Relay Block - I/P C1 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10360 Relay Block - I/P C1 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10361 Relay Block - I/P C1 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10362 Relay Block - I/P C1 Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10363 Relay Block - I/P C1 Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10364 Relay Block - I/P C1 Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10365 Relay Block - I/P C1 Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10366 Relay Block - I/P C3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10367 Relay Block - I/P C3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10368 Relay Block - I/P C4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10369 Relay Block - I/P C5 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10370 Relay Block - I/P C5 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10371 Relay Block - I/P C8 (With RPO Codes 5G4/5X7/5Y0/TRW) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10372 Relay Block - I/P C9 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10373 Relay Block - I/P C9 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10374 Relay Block - I/P C10 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10375 Relay Block - I/P C10 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 10376 Relay Block I/P C7 (With RPO Codes Z82 Or T89) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Fuse Block: Application and ID Fuse Block - I/P Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 10379 Application Tabel Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 10380 Application Tabel Part 2 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 10381 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 10382 Fuse Block: Application and ID Fuse Block - Underhood Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 10383 Application Table Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 10384 Application Table Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 10385 Application Table Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 10386 Application Table Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 10387 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 10388 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 10389 Fuse Block: Application and ID Fuse Block - Underhood - Secondary Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 10390 Application Table Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 10391 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 10392 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 10393 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 10394 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 10395 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 10396 Fuse Block - Underhood - Secondary Wire Entry (With RPO Code HP2) Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 10397 Fuse Block: Application and ID Junction Block - I/P Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 10398 Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 10399 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 10400 Junction Block - I/P Wire Entry Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 10401 Junction Block - I/P Wire Entry Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 10402 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10405 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10406 1. Install the engine electrical center bracket assembly to the front fender. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 4 retaining bolts (1). Tighten Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10407 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10408 Fuse Block: Service and Repair I/P Electrical Center or Junction Block Replacement - Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10409 8. Install the left side end panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10410 Fuse Block: Service and Repair I/P Electrical Center or Junction Block Replacement - Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolt. Tighten Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10411 4. Connect the wiring connectors to the fuse block. Refer to Electrical Center Identification Views to ensure the right connections are made. 5. Install the right side end panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10412 Fuse Block: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolts. Tighten Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10413 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Service and Repair Ground Strap: Service and Repair GROUND STRAP REPLACEMENT REMOVAL PROCEDURE 1. If necessary, remove the engine sight shield. 2. Remove the engine wiring harness ground bolt. 3. Reposition the engine wiring harness ground and ground strap. 4. Remove the ground strap nut from the stud at the front of dash. 5. Remove the ground strap from the stud. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Service and Repair > Page 10417 1. Install the ground strap to the stud. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ground strap nut to the stud at the front of dash. Tighten Tighten the nut to 9 N.m (80 lb in). 3. Position the ground strap and engine wiring harness ground. 4. Install the engine wiring harness ground bolt. Tighten Tighten the bolt to 16 N.m (12 lb ft). 5. If necessary, install the engine sight shield. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: Customer Interest Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 10426 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 10432 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 10433 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 10434 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 10435 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 10436 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 10437 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set Grounding Point: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set TECHNICAL Bulletin No.: 04-05-25-002E Date: March 11, 2009 Subject: ABS Light On, DTCs C0265, C0201, U1041 Set and/or Loss of Communication with Brake Module (Reground EBCM Ground) Models Supercede: This bulletin is being revised to add step 2 to the procedure and update the Parts and Warranty Information. Please discard Corporate Bulletin Number 04-05-25-002D (Section 05 - Brakes). Condition Some customers may comment that the ABS light is on. Upon further inspection, DTCs C0265 and C0201 may be set in the brake module. It is also possible for DTC U1041 to set in other modules. There may also be a loss of communication with the brake module. Cause A poor connection at the EBCM ground is causing unnecessary replacement of brake modules. Important: The EBCM ground is different for each application. Refer to the list below for the proper ground reference: ^ Midsize Utilities = Ground 304 ^ SSR = Ground 400 ^ Fullsize Trucks and Utilities = Ground 110 Correction Important: Do not replace the brake module to correct this condition. Perform the following repair before further diagnosis of the EBCM. Perform the following steps to improve the connection of the EBCM Ground: 1. Remove the EBCM Ground. The EBCM Ground is located on the frame beneath the driver's side door. If multiple grounds are found in this location, the EBCM ground can be identified as the heavy (12-gauge) wire. 2. If the original fastener has a welded on nut, remove the nut from the frame, and if required, enlarge the bolt hole to accommodate the new bolt and nut. 3. Clean the area, front and back, using a tool such as a *3M(TM) Scotch-Brite Roloc disc or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grounding Point: > 04-05-25-002E > Mar > 09 > Brakes - ABS Lamp ON/DTC's C0265/C0201/U1041 Set > Page 10442 4. Install the ground, then the washer and then the bolt to the frame. Important: It is important to use the bolts, washers and nuts specified in this bulletin. These parts have been identified due to their conductive finish. 5. Install a washer and nut to the back side of the frame. Tighten Tighten the nut to 9 Nm (79 lb in). 6. Cover the front and back side of the repair area using Rubberized Undercoating. An additional check can be made to ensure a good connection for the battery cable to frame ground. It is possible for this ground to cause similar symptoms with the ABS as described above. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Grounding Point: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10448 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10449 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10450 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10451 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10452 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > All Other Service Bulletins for Grounding Point: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10453 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 Multiple Junction Connector: Diagrams C100 - C198 C100 I/P Harness To Engine Harness Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10458 C100 I/P Harness To Engine Harness Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10459 C102 I/P Harness To Chassis Harness Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10460 C102 I/P Harness To Chassis Harness Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10461 C103 I/P Harness To Forward Lamp Harness (Export) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10462 C104 I/P Harness To Forward Lamp Harness (With RPO Code YE9) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10463 C104 I/P Harness To Forward Lamp Harness (With Out RPO Code YE9) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10464 C106 Engine Harness To I/P Harness (With RPO Code PTO) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10465 C107 Main Engine Harness To Engine Jumper Harness Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10466 C107 Main Engine Harness To Engine Jumper Harness Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10467 C107 Main Engine Harness To Engine Jumper Harness Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10468 C108 Main Engine Harness To Engine Jumper Harness Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10469 C108 Main Engine Harness To Engine Jumper Harness Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10470 C108 Main Engine Harness To Engine Jumper Harness Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10471 C113 Engine Jumper Harness To Engine Harness Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10472 C115 Chassis Harness To I/P Harness (With RPO Code NYS) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10473 C115 Chassis Harness To I/P Harness (With RPO Code NYS) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10474 C117 Battery Negative Harness To Accessory Jumper Harness (With RPO Code 9L4) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10475 C119 Accessory Jumper Harness To Brake/Clutch Harness (With RPO Code 9L4) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10476 C125 Snowplow Harness To Forward Lamp Harness (With RPO Code VYU) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10477 C127 Snowplow Harness To Forward Lamp Harness (With RPO Code VYU) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10478 C150 4-Wheel Drive Harness To 4-Wheel Drive Jumper Harness (With RPO Code NP8) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10479 C151 I/P Harness To ATC Harness (With RPO Codes NP1/NP8) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10480 C152 Chassis Harness To Engine Harness Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10481 C152 Chassis Harness To Engine Harness Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10482 C153 4-Wheel Drive Harness To Engine Harness Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10483 C154 I/P Harness To ATC Harness (With RPO Codes NP1/NP8) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10484 C160 Chassis Harness To Brake/Clutch Harness (With RPO Codes 5X7/5Y0) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10485 C161 Roof Beacon Harness To Chassis Harness (With RPO Code 5Y0) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10486 C198 I/P Harness To Chassis Harness Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10487 Multiple Junction Connector: Diagrams C201 - C277 C201 Steering Column Harness To I/P Harness Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10488 C201 Steering Column Harness To I/P Harness Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10489 C201 Steering Column Harness To I/P Harness Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10490 C201 Steering Column Harness To I/P Harness Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10491 C202 I/P Harness To Brake/Clutch Harness Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10492 C202 I/P Harness To Brake/Clutch Harness Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10493 C206 I/P Harness To Body Harness (With RPO Codes Y91/HP2) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10494 C206 I/P Harness To Body Harness (With RPO Codes Y91/HP2) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10495 C210 Brake/Clutch Harness To Beacon Harness (With RPO Codes 5G4/TRW) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10496 C214 I/P Harness To Headliner Harness (With RPO Code U42) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10497 C214 I/P Harness To Headliner Harness (With RPO Code U42) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10498 C214 Infotainment Harness To Headliner Harness (With RPO Code UE1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10499 C216 Brake/Clutch Harness To Fuse Block Jumper Harness (With RPO Code 9L4) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10500 C220 I/P Harness To Infotainment Jumper Harness (With RPO Code UQ7 & Without RPO Code Y91) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10501 C220 I/P Harness To Infotainment Jumper Harness (With RPO Code UQ7 & Without RPO Code Y91) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10502 C221 I/P Harness To Body Harness (With Single Stage Air Bag) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10503 C221 I/P Harness To Body Harness (With Dual Stage Air Bag) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10504 C222 I/P Harness To Body Harness Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10505 C223 I/P Harness To Body Harness (Except NYS And HP2) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10506 C223 I/P Harness To Body Harness (Except NYS And HP2) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10507 C230 I/P Harness (With RPO Codes UE1 And Y91) Or Infotainment Jumper Harness (With RPO Code UE1 & Without RPO Code Y91) To Roofmarker Harness Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10508 C249 I/P Harness To Bezel Harness (Except Y91) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10509 C249 Console Harness To Bezel Harness (With RPO Code Y91) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10510 C250 Brake/Clutch Harness To Brake Clutch Jumper Harness (With RPO Code ZX3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10511 C250 Brake/Clutch Harness To Brake Clutch Jumper Harness (With RPO Codes 5X7, 5G4, 5Y0, And TRW) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10512 C275 Steering Column Harness To Steering Wheel Module Coil (With RPO Code HVY) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10513 C275 Steering Column Harness To Steering Wheel Module Coil (With RPO Code AL0) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10514 C277 Steering Wheel Module Coil To Steering Wheel Harness (With RPO Code UK3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10515 Multiple Junction Connector: Diagrams C305 - C399 C305 Body Harness To Drivers Seat Harness (With RPO Code AG1) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10516 C305 Body Harness To Drivers Seat Harness (With RPO Code AG1) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10517 C306 Infotainment Jumper Harness To Console Harness (Without RPO Code Y91) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10518 C306 Infotainment Jumper Harness To Console Harness (Without RPO Code Y91) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10519 C306 Infotainment Jumper Harness To Console Harness (Without RPO Code Y91) Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10520 C306 Infotainment Jumper Harness To Console Harness (With RPO Code Y91) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10521 C306 Infotainment Jumper Harness To Console Harness (With RPO Code Y91) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10522 C306 Infotainment Jumper Harness To Console Harness (With RPO Code Y91) Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10523 C310 Body Harness To Left Rear Door Harness (Crew Cab) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10524 C310 Body Harness To Left Rear Door Harness (Crew Cab) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10525 C320 Seat Jumper Harness To Seat Harness (With RPO Code AN3) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10526 C320 Seat Jumper Harness To Seat Harness (With RPO Code AN3) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10527 C321 Seat Jumper Harness To Seat Harness (With RPO Code AN3) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10528 C321 Seat Jumper Harness To Seat Harness (With RPO Code AN3) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10529 C322 Seat Motor Jumper Harness To Seat Jumper Harness (With RPO Code AN3) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10530 C322 Seat Motor Jumper Harness To Seat Jumper Harness (With RPO Code AN3) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10531 C323 Seat Motor Jumper Harness To Seat Jumper Harness (With RPO Code AG1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10532 C324 Lumbar Bolster Harness To Seat Harness (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10533 C325 Heated Seat Jumper Harness To Seat Jumper Harness (With RPO Code KA1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10534 C326 Heated Seat Jumper Harness To Passenger Seat Harness (With RPO Code KA1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10535 C329 Lumbar Bolster Harness To Passenger Seat Harness (With RPO Code AG2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10536 C330 Body Harness To Passenger Seat Harness (With RPO Code AL0) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10537 C388 Seat Motor Jumper Harness To Passenger Seat Harness (With RPO Code AG2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10538 C396 Body Harness To Right Rear Door Harness (Crew Cab) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10539 C396 Body Harness To Right Rear Door Harness (Crew Cab) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10540 C399 Body Harness To Passenger Seat Harness Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10541 C399 Body Harness To Passenger Seat Harness Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10542 Multiple Junction Connector: Diagrams C404 - C411 C404 Left Clearance Lamp Harness To License Lamp Harness (With RPO Codes NYS Or R05) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10543 C405 Right Clearance Lamp Harness To License Lamp Harness (With RPO Codes NYS Or R05) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10544 C410 Right Rear Lamp Harness To Chassis Harness (With RPO Code T79) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C198 > Page 10545 C411 Left Rear Lamp Harness To Chassis Harness (With RPO Code T79) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P Relay Box: Locations Junction Block - I/P Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10551 Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10552 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10553 Junction Block - I/P Wire Entry Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10554 Junction Block - I/P Wire Entry Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10555 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10556 Relay Box: Locations Relay Block - I/P Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10557 Application Table Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10558 Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 10559 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 10560 Junction Block - Rear Lamps - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 10561 Junction Block - Rear Lamps - C3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 10562 Junction Block - Rear Lamps - C4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P Relay Box: Application and ID Junction Block - I/P Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10565 Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10566 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10567 Junction Block - I/P Wire Entry Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10568 Junction Block - I/P Wire Entry Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10569 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10570 Relay Box: Application and ID Relay Block - I/P Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10571 Application Table Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10572 Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10575 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10576 1. Install the engine electrical center bracket assembly to the front fender. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 4 retaining bolts (1). Tighten Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10577 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10578 Relay Box: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolts. Tighten Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10579 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10580 Relay Box: Service and Repair I/P Electrical Center or Junction Block Replacement - Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10581 8. Install the left side end panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10582 Relay Box: Service and Repair I/P Electrical Center or Junction Block Replacement - Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolt. Tighten Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10583 4. Connect the wiring connectors to the fuse block. Refer to Electrical Center Identification Views to ensure the right connections are made. 5. Install the right side end panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P Relay Box: Locations Junction Block - I/P Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10588 Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10589 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10590 Junction Block - I/P Wire Entry Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10591 Junction Block - I/P Wire Entry Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10592 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10593 Relay Box: Locations Relay Block - I/P Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10594 Application Table Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Junction Block - I/P > Page 10595 Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 10596 Relay Box: Diagrams Junction Block - Rear Lamps - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 10597 Junction Block - Rear Lamps - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 10598 Junction Block - Rear Lamps - C3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 10599 Junction Block - Rear Lamps - C4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P Relay Box: Application and ID Junction Block - I/P Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10602 Junction Block - I/P Wire Entry Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10603 Junction Block - I/P Wire Entry Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10604 Junction Block - I/P Wire Entry Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10605 Junction Block - I/P Wire Entry Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10606 Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10607 Relay Box: Application and ID Relay Block - I/P Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10608 Application Table Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Junction Block - I/P > Page 10609 Location View Location View Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left fender upper brace. 3. Remove the electrical center brace cover assemble by lifting the cover (3) outwards to clear the tabs. 4. Remove all fuses and relays. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10612 5. Push on the tab (3) so that the electrical center can be rotated on the studs located at (2). 6. Remove all connectors by removing the bolt (1) for each connector. 7. Disconnect all connectors from the electrical center block. 8. Push on the tabs (2) in order to lift the electrical center (1) out of the housing. 9. To replace the engine electrical center bracket remove the 4 retaining bolts (1). 10. Remove the engine electrical center bracket assembly from the fender. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10613 1. Install the engine electrical center bracket assembly to the front fender. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 4 retaining bolts (1). Tighten Tighten the 4 retaining bolts (1) to 9 N.m (80 lb in). 3. Align the electrical center block (1) stubs in the slots so that the tabs (2) retains it in place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10614 4. Connect the wire connectors to the lower portion of the electrical center block. 5. Connect the wire connectors with the bolts to the electrical center block. Tighten Tighten all connector bolts (1) to 9 N.m (80 lb in). 6. Ensure all wire connectors are securely connected. 7. Set the electrical center block in its resting position till the tabs (3) locks in place. 8. Install the lower part of the cover (1). 9. With the cover (2) off, use the fuse location information to install all fuses and relays. 10. Install the cover. 11. Install the fender upper brace. 12. Install the 4 fender upper brace bolts. Tighten Tighten the 4 retaining bolts to 25 N.m (18 lb ft). 13. Connect the negative battery cable. 14. Start vehicle and ensure all components function properly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10615 Relay Box: Service and Repair Body Wiring Harness Junction Block Replacement BODY WIRING HARNESS JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover retaining nut. 2. Remove the cover by pushing in the tabs. 3. Remove the harness from the front of the junction block. 4. Remove the junction block from the bracket by pressing to release the tabs. 5. Remove the junction block in order to gain access to the rear of the block to remove the retaining bolts. 6. Remove the retaining bolts. 7. Separate the wire harness block from the junction block by inserting a screw driver in between. 8. Remove the junction block from the vehicle. INSTALLATION PROCEDURE 1. Install the wire harness block to the junction block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolts. Tighten Tighten the bolts to 6 N.m (53 lb in). 3. Install the junction block to the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10616 4. Push on the top part until it clicks in place. 5. Connect the harness to the front of the junction block. 6. Install the cover to the junction block until it clicks in place. 7. Hand tighten the retaining nut until seated. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10617 Relay Box: Service and Repair I/P Electrical Center or Junction Block Replacement - Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left side end panel. 2. Remove the knee bolster. 3. Disconnect all the wiring connectors from the fuse block. 4. Remove all the fuses. 5. Remove the turn signal relay from the back of the fuse block. 6. From behind the fuse block, remove the retaining bolt. 7. Insert a screw driver between the fuse block and the wire harness block to separate. 8. Push on the retainers in order to remove the fuse block. 9. Remove the fuse block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block onto the I/P assembly until it clicks in place. 2. Install the wire harness block to the back of the fuse block. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). 4. Install the turn signal relay to the back of the fuse block. 5. Using the wiring diagram on the cover of the fuse panel, install the fuses. 6. Install the electrical connectors. 7. Install the knee bolster. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10618 8. Install the left side end panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10619 Relay Box: Service and Repair I/P Electrical Center or Junction Block Replacement - Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side end panel. 2. Push in the tabs in order to remove the fuse block. 3. Pull out the fuse block out of the I/P in order to remove the retaining bolt. 4. Loosen the bolt. 5. Insert a screw driver between the wire harness block and fuse block in order to separate. 6. Separate the fuse block from the I/P harness block. 7. Remove the I/P wiring harness block from the vehicle. INSTALLATION PROCEDURE 1. Install the fuse block to the I/P wire harness block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining bolt. Tighten Tighten the bolt to 6 N.m (53 lb in) 3. Install the fuse block to the I/P until it clicks in place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 10620 4. Connect the wiring connectors to the fuse block. Refer to Electrical Center Identification Views to ensure the right connections are made. 5. Install the right side end panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10629 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10630 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10631 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-04-034 > Aug > 09 > Fuel System - Reduced Engine Power, MIL (Various Codes) Wiring Harness: Customer Interest Fuel System - Reduced Engine Power, MIL (Various Codes) TECHNICAL Bulletin No.: 09-06-04-034 Date: August 17, 2009 Subject: Malfunction Indicator Lamp (MIL) Illuminated, Fuel Injector Driver Circuit DTCs P0201, P0202, P0203, P0204, P0205, P0206, P0207, P0208 and Cylinder Bank Shut Down DTCs P2146 or P2149, Reduced Engine Power (Repair Fuel Injector Control Module (FICM) Harness Chafed Wires) Models: 2001-2004 Chevrolet Kodiak C4500/C5500 Series, Silverado Models 2001-2004 GMC Sierra Models, TopKick C4500/C5500 Series Equipped with Duramax(TM) Diesel Engine RPO LB7 2004-2005 Chevrolet Kodiak, Silverado Models 2004-2005 GMC Sierra Models, TopKick Equipped with Duramax Diesel Engine RPO LLY Please Refer to GMVIS Condition Some customers may comment that the malfunction indicator lamp (MIL) is illuminated or intermittent and there is a significant reduction in engine power (limp home mode). The scan tool may display one or more Injector Driver Circuit DTCs P0201, P0202, P0203, P0204, P0205, P0206, P0207 or P0208 and/or Cylinder Bank Shut Down DTCs P2146 or P2149 set as Current or in History. Cause This condition may be caused by the fuel injector control module (FICM) wiring harness protective conduit rubbing against the back of the alternator, the alternator bracket or the FICM harness retaining bracket. This may result in the conduit rubbing through, exposing the wires inside and chafing of the wire insulation then occurs. Correction 1. Turn ON the ignition, with the engine OFF. 2. Observe the DTC information with the scan tool. 3. If any of the above DTCs are set, then proceed to inspect the FICM wiring harness at the locations outlined in the following steps. 4. Turn OFF the ignition and all accessories and allow the control modules to power down. Note For Silverado and Sierra models only perform Step 5. 5. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. Important DO NOT break off the tab on the electrical connectors. 6. Disconnect the FICM electrical connectors (2) from the FICM (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-04-034 > Aug > 09 > Fuel System - Reduced Engine Power, MIL (Various Codes) > Page 10636 7. Carefully bend up and backwards the FICM wiring harness electrical connectors (1) away from the FICM (4). Note Some of these chafes are very small, possibly the size of a pen tip, but could still cause injector circuit concerns. 8. Inspect the wiring harness for chafing (3) that may result from rubbing at the back of the alternator (2), the alternator bracket or at the FICM harness retaining bracket. If necessary, peel the tape from the area and look for ANY chafes into the wires. ^ If chafing is observed and the conductive portion of the wire IS NOT damaged, apply electrical tape around the wire. ^ If chafing is observed and the conductive portion of the wire IS damaged, then refer to Splicing Copper Wire Using Splice Sleeves in Wiring Repairs in SI. ^ If chafing IS NOT OBSERVED, then refer to the appropriate DTC Diagnostic procedures in SI. 9. Connect the electrical connectors to the FICM. 10. Insulate the harness with suitable material such as conduit or heater hose to prevent a reoccurrence. Note For Silverado and Sierra models only perform Step 11. 11. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 12. Clear the DTCs with a scan tool. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-50-014A > Jan > 06 > Electrical - No Module Communication/DTCs/Warning Lamps Wiring Harness: Customer Interest Electrical - No Module Communication/DTCs/Warning Lamps Bulletin No.: 03-08-50-014A Date: January 20, 2006 TECHNICAL Subject: No Communication with Any Modules, Memory Seat May Not Recall, Multiple U-DTCs Set or Instrument Panel Cluster (IPC) Warning Indicators, Crank No Start (Inspect/Repair Affected Wiring Harness) Models: 2003-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL with Front, Individual (Non-Bkt) Seat (RPO AN3) and/or Active Brake Control (Stabilitrak(R)) (RPO JL4) Supercede: This bulletin is being revised to update the various conditions and add the 2004-2006 model years, additional diagnostic and warranty information. Please discard Corporate Bulletin Number 03-08-50-014 (Section 08 - Body & Accessories). Condition Some customers may comment on any of the following conditions: ^ Various IPC Warning indicators are coming on. ^ Driver Information Center (DIC) displays "Unknown Driver". ^ Memory seat may not recall. ^ RKE fobs may be inoperative. ^ Radio or HVAC may shut off. ^ Engine cranks but will not start. Upon investigation, the Technician may find multiple U-DTCs set. Cause On RPO AN3 equipped vehicles, a chafed or pinched seat wiring harness under the driver seat may be a cause of this condition. Because of the routing, a portion of the seat wiring harness may rest on the inboard edge of the seat track or frame. Over time, the harness may be pinched or chafed because of the seat movement. Refer to the above illustration. The illustration shows the inverted position of the seat bottom. The arrow shows the primary location Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-50-014A > Jan > 06 > Electrical - No Module Communication/DTCs/Warning Lamps > Page 10641 of the possible harness chafing/pinching. Also, on any of the above listed vehicles, the PCM wiring harness may be chafing against the precharge pump bracket or the battery tray. Correction On RPO AN3 vehicles, inspect the routing of the seat wiring harness. Reroute the seat wiring harness and attaching harness fastener (1) to the opposite side of the seat module bracket. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. The seat may have to be removed for ease of access and proper repair of the wiring harness. Inspect the routing of the PCM wiring harness at the precharge pump bracket and the battery tray. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. If any of the above conditions still remain after this repair, refer to SI for further diagnostic information. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10647 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10648 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 10649 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10654 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10655 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10656 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10657 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10658 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10659 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-04-034 > Aug > 09 > Fuel System - Reduced Engine Power, MIL (Various Codes) Wiring Harness: All Technical Service Bulletins Fuel System - Reduced Engine Power, MIL (Various Codes) TECHNICAL Bulletin No.: 09-06-04-034 Date: August 17, 2009 Subject: Malfunction Indicator Lamp (MIL) Illuminated, Fuel Injector Driver Circuit DTCs P0201, P0202, P0203, P0204, P0205, P0206, P0207, P0208 and Cylinder Bank Shut Down DTCs P2146 or P2149, Reduced Engine Power (Repair Fuel Injector Control Module (FICM) Harness Chafed Wires) Models: 2001-2004 Chevrolet Kodiak C4500/C5500 Series, Silverado Models 2001-2004 GMC Sierra Models, TopKick C4500/C5500 Series Equipped with Duramax(TM) Diesel Engine RPO LB7 2004-2005 Chevrolet Kodiak, Silverado Models 2004-2005 GMC Sierra Models, TopKick Equipped with Duramax Diesel Engine RPO LLY Please Refer to GMVIS Condition Some customers may comment that the malfunction indicator lamp (MIL) is illuminated or intermittent and there is a significant reduction in engine power (limp home mode). The scan tool may display one or more Injector Driver Circuit DTCs P0201, P0202, P0203, P0204, P0205, P0206, P0207 or P0208 and/or Cylinder Bank Shut Down DTCs P2146 or P2149 set as Current or in History. Cause This condition may be caused by the fuel injector control module (FICM) wiring harness protective conduit rubbing against the back of the alternator, the alternator bracket or the FICM harness retaining bracket. This may result in the conduit rubbing through, exposing the wires inside and chafing of the wire insulation then occurs. Correction 1. Turn ON the ignition, with the engine OFF. 2. Observe the DTC information with the scan tool. 3. If any of the above DTCs are set, then proceed to inspect the FICM wiring harness at the locations outlined in the following steps. 4. Turn OFF the ignition and all accessories and allow the control modules to power down. Note For Silverado and Sierra models only perform Step 5. 5. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. Important DO NOT break off the tab on the electrical connectors. 6. Disconnect the FICM electrical connectors (2) from the FICM (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-04-034 > Aug > 09 > Fuel System - Reduced Engine Power, MIL (Various Codes) > Page 10664 7. Carefully bend up and backwards the FICM wiring harness electrical connectors (1) away from the FICM (4). Note Some of these chafes are very small, possibly the size of a pen tip, but could still cause injector circuit concerns. 8. Inspect the wiring harness for chafing (3) that may result from rubbing at the back of the alternator (2), the alternator bracket or at the FICM harness retaining bracket. If necessary, peel the tape from the area and look for ANY chafes into the wires. ^ If chafing is observed and the conductive portion of the wire IS NOT damaged, apply electrical tape around the wire. ^ If chafing is observed and the conductive portion of the wire IS damaged, then refer to Splicing Copper Wire Using Splice Sleeves in Wiring Repairs in SI. ^ If chafing IS NOT OBSERVED, then refer to the appropriate DTC Diagnostic procedures in SI. 9. Connect the electrical connectors to the FICM. 10. Insulate the harness with suitable material such as conduit or heater hose to prevent a reoccurrence. Note For Silverado and Sierra models only perform Step 11. 11. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 12. Clear the DTCs with a scan tool. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 10669 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 03-08-50-014A > Jan > 06 > Electrical - No Module Communication/DTCs/Warning Lamps Wiring Harness: All Technical Service Bulletins Electrical - No Module Communication/DTCs/Warning Lamps Bulletin No.: 03-08-50-014A Date: January 20, 2006 TECHNICAL Subject: No Communication with Any Modules, Memory Seat May Not Recall, Multiple U-DTCs Set or Instrument Panel Cluster (IPC) Warning Indicators, Crank No Start (Inspect/Repair Affected Wiring Harness) Models: 2003-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL with Front, Individual (Non-Bkt) Seat (RPO AN3) and/or Active Brake Control (Stabilitrak(R)) (RPO JL4) Supercede: This bulletin is being revised to update the various conditions and add the 2004-2006 model years, additional diagnostic and warranty information. Please discard Corporate Bulletin Number 03-08-50-014 (Section 08 - Body & Accessories). Condition Some customers may comment on any of the following conditions: ^ Various IPC Warning indicators are coming on. ^ Driver Information Center (DIC) displays "Unknown Driver". ^ Memory seat may not recall. ^ RKE fobs may be inoperative. ^ Radio or HVAC may shut off. ^ Engine cranks but will not start. Upon investigation, the Technician may find multiple U-DTCs set. Cause On RPO AN3 equipped vehicles, a chafed or pinched seat wiring harness under the driver seat may be a cause of this condition. Because of the routing, a portion of the seat wiring harness may rest on the inboard edge of the seat track or frame. Over time, the harness may be pinched or chafed because of the seat movement. Refer to the above illustration. The illustration shows the inverted position of the seat bottom. The arrow shows the primary location Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 03-08-50-014A > Jan > 06 > Electrical - No Module Communication/DTCs/Warning Lamps > Page 10674 of the possible harness chafing/pinching. Also, on any of the above listed vehicles, the PCM wiring harness may be chafing against the precharge pump bracket or the battery tray. Correction On RPO AN3 vehicles, inspect the routing of the seat wiring harness. Reroute the seat wiring harness and attaching harness fastener (1) to the opposite side of the seat module bracket. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. The seat may have to be removed for ease of access and proper repair of the wiring harness. Inspect the routing of the PCM wiring harness at the precharge pump bracket and the battery tray. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. If any of the above conditions still remain after this repair, refer to SI for further diagnostic information. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10680 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10681 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10682 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10683 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10684 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 10685 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 10690 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 10696 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 10697 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 10698 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 10699 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 10700 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 10701 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 10702 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 10703 Alignment: Technical Service Bulletins Steering/Suspension - Revised Caster/Camber Adjustment Info - Revised Front Caster and Camber Adjustment Procedure # 02-03-07-002A - (Mar 24, 2005) Models: 1999-2000 Cadillac Escalade 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Express, Silverado, Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999 GMC Suburban 1999-2005 GMC Savana, Sierra, Yukon, Yukon XL, Yukon XL Denali This bulletin is being revised to add model years and clarify the information. Please discard Corporate Bulletin Number 02-03-07-002 (Section 03 - Suspension). When performing a wheel alignment on any of the above vehicles, please refer to the Front Caster and Camber Adjustment Procedure in SI before contacting the GM Technical Assistance Center (TAC) with issues concerning adjustments, caster out-of-spec, etc. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Trim Height Specifications Alignment: Specifications Trim Height Specifications Trim Height Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Trim Height Specifications > Page 10706 Alignment: Specifications Wheel Alignment Specifications Wheel Alignment Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Trim Height Specifications > Page 10707 Alignment: Specifications Fastener Tightening Specifications Fastener Tightening Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 10708 Alignment: Description and Operation Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 10709 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Lead/Pull Description Definition: At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Lead/pull is usually caused by the following factors: ^ Tire construction ^ Wheel alignment ^ Unbalanced steering gear The way in which a tire is built may produce lead/pull. The rear tires will not cause lead. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 10710 Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure Alignment: Service and Repair Trim Height Inspection Procedure Trim Height Inspection Procedure Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: 1. Make sure the vehicle is on a level surface, such as a alignment rack. 2. Remove the alignment rack floating pins. 3. Set the tire pressures to the pressure shown on the certification label. 4. Check the fuel level. Add additional weight if necessary to simulate a full tank. 5. Make sure the rear compartment is empty except for the spare tire. 6. Close the doors and hood. Z Height Measurement Important: K models only the Z height must be adjusted before the alignment. The Z height dimension measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use a adjusting arm in order to adjust the Z height dimension. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. 1. Important: All dimensions are measured vertical to the ground. Cross vehicle Z heights should be within 12 mm (0.47 inch) to be considered correct. Place hand on the front bumper and jounce the front of the vehicle. Make sure that there is at least 38 mm (1.5 inch) of movement while jouncing. 2. Allow the vehicle to settle into position. 3. Measure from the pivot bolt center line (2) down to the lower corner (5) of the steering knuckle (1) in order to obtain the Z height measurement (4). 4. Repeat the jouncing operation 2 more times for a total of 3 times. 5. Use the highest and the lowest measurements to calculate the average height. 6. The true Z height dimension number is the average of the highest and the lowest measurements. Refer to Trim Height Specifications. Z Height Adjustment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 10713 1. For vehicles equipped with a torsion bar suspension turn the bolt (1) that contacts the torsion arm clockwise to raise the and counterclockwise to lower the height adjustment. One revolution of the bolt (1) into the nut increases the Z height by approximately 6.0 mm (0.2 inch). 2. For vehicles without torsion bars, replace damaged or worn components as necessary. D Height Measurement Important: There are no specified trim heights specifications on leaf spring vehicles because it is not an adjustable feature. The height of the suspension will depend on the option content of the vehicle as well as the aftermarket equipment that is placed on the vehicle. The measurements are used for comparison only and should be within 15 mm with the vehicle at curb and no accessories. 1. With the vehicle on a flat surface, lift upward on the rear bumper 38 mm (1.5 inch). 2. Allow the vehicle to settle into position. 3. Important: Measure the metal to metal contact points of the rear axle to the frame on the inboard side of the leaf springs. Measure the D height by measuring the distance between the bumper bracket and the top of the rear axle tube. 4. Repeat the jouncing operation 2 more times for a total of 3 times. 5. Use the highest and lowest measurements to calculate the average height. 6. The true D height dimension number is the average of the highest and the lowest measurements. 7. If these measurements are out of specifications, inspect for the following conditions: ^ Sagging front suspension Refer to Front Coil Springs Replacement or Torsion Bar Replacement in Front Suspension. ^ Sagging rear leaf/coil springs Refer to Leaf Spring Replacement in Rear Suspension. ^ Worn rear suspension components, such as leaf spring bushings Refer to Spring Bushing Replacement in Rear Suspension. ^ Improper tire inflation Refer to Tire Inflation Pressure Specifications. ^ Improper weight distribution ^ Collision damage Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 10714 Alignment: Service and Repair Measuring Wheel Alignment (W/Rear Wheel Steering) Measuring Wheel Alignment (w/Rear Wheel Steering) Learn Wheel Alignment After replacement of the handwheel position sensor, rear wheel position sensor, or rear wheel steering control module it is necessary to perform the learn wheel alignment procedure. Alignment Procedure Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: at a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicles straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in Tires and Wheels in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: ^ Inspect the tires for the proper inflation and irregular tire wear. ^ Inspect the runout of the wheels and the tires. ^ Inspect the wheel bearings for backlash and excessive play. ^ Inspect the ball joints and tie rod ends for looseness or wear. ^ Inspect the control arms and stabilizer shaft for looseness or wear. ^ Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications in Power Steering System. ^ Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Struts or Shock Absorbers On-Vehicle Testing in Suspension General Diagnosis. ^ Inspect the vehicle trim height. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis. ^ Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. ^ Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. 4. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications then perform the learn alignment procedure. Learn Wheel Alignment Procedure 1. Turn ignition to ON position, with the engine ON. 2. Install the scan tool. 3. Center the steering wheel. 4. Lift the rear of the vehicle off the ground ensuring the rear wheels are centered. 5. Go to the Learn Alignment menu choice in the scan tool. Follow the prompts on the scan tool. Important: When prompted by the scan tool you must turn the steering wheel a full 90 degrees to the left and a full 90 degrees to the right and then to center and hold. If this step is not done properly then it is possible to cause a false DTC for the steering wheel position sensor. 6. Press the continue button. 7. Use the scan tool to clear all rear wheel steering DTCs. (W/O Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 10715 Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: at a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicles straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in Tires and Wheels in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: ^ Inspect the tires for the proper inflation and irregular tire wear. ^ Inspect the runout of the wheels and the tires. ^ Inspect the wheel bearings for backlash and excessive play. ^ Inspect the ball joints and tie rod ends for looseness or wear. ^ Inspect the control arms and stabilizer shaft for looseness or wear. ^ Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications in Power Steering System. ^ Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Struts or Shock Absorbers On-Vehicle Testing in Suspension General Diagnosis. ^ Inspect the vehicle trim height. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis. ^ Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. ^ Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. 4. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 10716 Alignment: Service and Repair Front Wheel Alignment Front Caster and Camber Adjustment Front Caster and Camber Adjustment 1. Important: Caster measurements or valves must be compensated for the measured frame angle. Caster is relative to frame, the caster values must be compensated for the measured frame angle by using a digital protractor or equivalent on a flat portion of the frame in front of the rear tire. 2. Frame angle is positive when higher in the rear. Measure both sides of the frame and take an average from those measurements. Then add the average frame angle to the caster reading when making adjustments. 3. Frame angle is negative when lower in the rear. Measure both sides of the frame and take an average from the measurements. Then subtract the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 10717 average frame angle from the caster reading when making adjustments. 4. The caster and camber adjustments are made by rotating the offset cam bolt and the cam in the slotted frame bracket in order to reposition the control arm. Important: Before adjusting the caster and camber angles, jounce the front bumper three times to allow the vehicle to return to normal height. Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension is indicated in Trim Heights. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis. For an accurate reading, do not push or pull on the tires during the alignment process. 5. Determine the caster angle (2). Be sure to compensate for frame angle where required. 6. Determine the positive camber (2) or negative camber (3) angle. 7. Remove the pinned adjusting cam insert. Do not reinstall the cam insert. 8. Loosen the upper control arm cam adjustment bolts. Notice: Refer to Fastener Notice in Service Precautions. 9. Adjust the caster and the camber angle by turning the cam bolts until the specifications have been met.When the adjustments are complete, hold the cam bolt head in order to ensure the cam bolt position does not change while tightening the nut. ^ Tighten the cam nuts to 190 Nm (140 ft. lbs.). 10. Verify that the caster and the camber are still within specifications. Refer to Wheel Alignment Specifications. When the caster and camber are within specifications, adjust the toe. Refer to Front Toe Adjustment. Front Toe Adjustment Front Toe Adjustment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 10718 1. Loosen the jam nut on the tie rod (2). 2. Rotate the inner tie rod (1) to the required toe specification setting. Refer to Wheel Alignment Specifications. 3. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the jam nut on the tie rod. ^ Tighten the tie rod jam to 68 Nm (50 ft. lbs.). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Rear Toe Adjustment Rear Toe Adjustment 1. Loosen the jam nut on the tie rod (1). 2. Rotate the inner tie rod to the required toe specification setting. Refer to Wheel Alignment Specifications. 3. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the jam nut on the tie rod. ^ Tighten the tie rod jam to 65 Nm (48 ft. lbs.). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement Steering Control Module: Service and Repair Rear Wheel Steering Control Module Bracket Replacement Rear Wheel Steering Control Module Bracket Replacement Removal Procedure 1. Remove the rear wheel steering control module from the bracket. 2. Remove the bolts retaining the bracket (2) to the frame. 3. Remove the bracket (2) from the vehicle. Installation Procedure 1. Install the bracket (2) to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts retaining the bracket (2) to the frame. ^ Tighten the bracket retaining bolts to 10 Nm (81 inch lbs.). 3. Install the rear wheel steering control module to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement > Page 10725 Steering Control Module: Service and Repair Rear Wheel Steering Control Module Replacement Rear Wheel Steering Control Module Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the spare tire from the vehicle to gain access to the control module. 3. Disconnect the electrical connectors from the control module. 4. Remove the bolts (1) retaining the control module (2) to the bracket. 5. Remove the control module from the vehicle. Installation Procedure 1. Install the control module to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the control module (2) retaining bolts (1). ^ Tighten the bolts to 24 Nm (18 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement > Page 10726 3. Connect the electrical connectors to the module. 4. Program the control module. Refer to Service Programming System (SPS) in Programming. 5. Install the spare tire to the vehicle. 6. Lower the vehicle. 7. Perform a learn alignment. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Rear Wheel Steering Switch > Component Information > Service and Repair Rear Wheel Steering Switch: Service and Repair Rear Wheel Steering Mode Switch Replacement Removal Procedure 1. Remove the dash trim bezel. 2. Grasp the rear wheel steering mode switch housing (2) and pull outward to remove the switch assembly. 3. Disconnect the electrical connector (3) from the rear wheel steering mode switch. 4. Remove the rear wheel steering mode switch assembly (1) from the vehicle. Installation Procedure 1. Reconnect the rear wheel steering mode switch (3) electrical connectors. 2. Install the rear wheel steering mode switch (1) into the dash. 3. Reinstall the dash trim bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Rear Position Sensor Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the steering gear protection shield (1) retaining bolts (3). 3. Disconnect the electrical connector (1). 4. Notice: When removing the rear position cover from the steering gear be careful not to damage to the rear position sensor. Remove the rear wheel position sensor cover (4) from the steering gear by prying on the cover using the slot. 5. Remove the rear wheel position sensor retaining bolts (3). 6. Important: Check the inner tie rod boot for wear or damage. If the boots are damaged replace the steering gear actuator. 7. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Page 10744 Maintain the sensor position. Do not turn the sensor. Remove the rear wheel position sensor (2) from the steering gear. Installation Procedure 1. Important: Make sure the O-ring (1) is installed. Install the rear wheel position sensor (2) to the steering gear. 2. Important: Be careful to maintain the position of the replacement sensor. Remove the pin retaining the position of the new sensor and immediately install the sensor to the steering gear. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear wheel position sensor retaining bolts. Apply LOCTITE 242 blue. ^ Tighten the bolts to 4 Nm (35 inch lbs.). 4. Install the rear wheel position sensor cover (4). 5. Connect the electrical connector (1). 6. Install the steering gear protection shield (1) and retaining bolts (3). ^ Tighten the steering gear protection shield retaining bolts to 180 Nm (132 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Page 10745 7. Lower the vehicle. 8. Perform a four wheel alignment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Column Position Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement (Centering Required) ^ Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure 1. Set the front wheels in the straight-ahead position. 2. Install J 42640 or set the steering wheel in the LOCKED position. 3. Caution: Refer to SIR Caution in Service Precautions. Disconnect the negative battery cable. 4. Disable the SIR. 5. Important: You MUST make an alignment mark on the upper intermediate shaft to the steering column shaft, where they connect. You will need the alignment marks for installation. Make an alignment mark on the upper intermediate shaft and the steering column shaft, where they connect, before removal. 6. Remove the nut and the bolt from the upper to the lower steering shaft connection. Slide the lower shaft down. 7. Remove the steering wheel position sensor connector by using a suitable tool in order to pull the connector down around the right side of the steering column for accessibility. 8. Important: Do not apply force to the steering wheel position sensor and the adapter and bearing assembly in a sideways direction. If reusing the existing steering wheel position sensor, it MUST be centered before removal. Verify the type of steering wheel position sensor before removal. Refer to Steering Wheel Position Sensor Centering. 9. Remove the steering wheel position sensor and adapter and bearing assembly from the steering column jacket by pulling the assembly straight out. 10. Remove the steering wheel position sensor from the clips in the adapter and bearing assembly. Installation Procedure 1. Important: A new sensor MUST come with a pin installed. If pin is not installed, return and reorder sensor. Verify the following before installing the steering wheel position sensor: ^ The front wheels are in the straight-ahead position. ^ That J 42640 is installed or the steering wheel is in the LOCKED position. 2. If reusing the existing steering wheel position sensor, verify the type of sensor you have before installing. Refer to Steering Wheel Position Sensor Centering. 3. Install the steering wheel position sensor into the adapter and bearing assembly. 4. Install the adapter and bearing assembly into the steering column jacket. 1. Align the notches on the adapter and bearing assembly and the steering column jacket. 2. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10750 Do not apply force to the steering wheel position sensor and the adapter and bearing assembly in a sideways direction. Seat the adapter and bearing assembly into the steering column jacket. 5. Connect the steering wheel position sensor connector. 6. Notice: Refer to Fastener Notice in Service Precautions. Align the marks on the upper intermediate shaft and the steering column shafts, where they connect, that you made during the removal procedure. 7. Install the intermediate shaft to the steering column pinch bolt. ^ Tighten the nut to 62 Nm (46 ft. lbs.). 8. Connect the negative battery cable. 9. Enable the SIR system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10751 Steering Column Position Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure 1. Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. 3. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) 7. Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10752 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note location of the pin hole. ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin. Note the location of the pin hole. ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10753 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure 1. Important: If reusing the existing sensor, no centering of the sensor is required. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right.From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin. Note the location of the pin hole. ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10754 ^ A foam ring (3) ^ An alignment tab (2) for installing into the adapter and bearing assembly ^ A view of the inside of the connector 7. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin. Note location of the pin hole. ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 11. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 15. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10755 until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 19. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin. Note location of the pin hole. ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 23. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10756 Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10757 Steering Column Position Sensor: Service and Repair Inflatable Restraint Steering Wheel Module Coil Centering Inflatable Restraint Steering Wheel Module Coil Centering 1. Notice: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction. Important: If double wire harness strap is installed onto the wire harness assembly and column, you must reuse the holder for the wire straps during installation. Remove the wire harness strap(s) where necessary. Verify the following conditions before centering the SIR coil: ^ The wheels on the vehicle are straight ahead. ^ The block tooth (1) of the steering shaft assembly is in the 12 o'clock position. ^ The ignition switch is in the LOCK position. 2. If the front (5) of the SIR coil has a centering window (4), and the back side (2) includes a spring service lock (1), perform the following steps: 1. Hold the SIR coil with the face up. 2. While depressing the spring service lock, rotate the coil hub clockwise until the coil ribbon stops. 3. Rotate the coil hub slowly, counterclockwise, until the centering window appears yellow and both arrows (3) line up. 4. Release spring service lock between the locking tab. The SIR coil is now centered. 5. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 3. If the front (4) of the SIR coil has a centering window (3), and the back side (1) includes NO spring service lock, perform the following steps: 0. Hold the SIR coil with the face up. 1. Rotate the coil hub clockwise until the coil ribbon stops. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10758 2. Rotate the coil hub slowly, counterclockwise until the centering window appears yellow and both arrows (2) line up. This is the CENTER position. 3. While holding the coil hub in the CENTER position, align the SIR coil with the horn tower and slide onto the steering shaft assembly. 4. If the front side (3) of the SIR coil has NO centering window, but the back side (2) includes a spring service lock (1), perform the following steps: 0. Hold the SIR coil with the back side up. 1. While depressing the spring service lock, rotate the coil hub in the direction of the arrow (4) until the coil ribbon stops. 2. Still pressing the spring service lock, rotate the coil hub in the opposite direction 21⁄2 revolutions. 3. Release the spring service lock between locking tabs. The SIR coil is now centered. 4. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 5. If the front side (2) of the SIR coil has NO centering window, and the back side (1) includes NO spring service lock, perform the following steps: 0. Hold the SIR coil with the face up. 1. Rotate the coil hub in the direction of the arrow until the coil ribbon stops. 2. Rotate the coil hub, slowly, counterclockwise, for 21⁄2 revolutions. This is the CENTER position. 3. While maintaining the coil hub in the CENTER position, align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 6. If double wire harness strap is installed onto the wire harness assembly and column, you must route the wires up against the steering column. One wire harness strap will surround one lead from the coil to the steering column. The other wire harness strap will surround all leads to the steering column. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Rear Position Sensor Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the steering gear protection shield (1) retaining bolts (3). 3. Disconnect the electrical connector (1). 4. Notice: When removing the rear position cover from the steering gear be careful not to damage to the rear position sensor. Remove the rear wheel position sensor cover (4) from the steering gear by prying on the cover using the slot. 5. Remove the rear wheel position sensor retaining bolts (3). 6. Important: Check the inner tie rod boot for wear or damage. If the boots are damaged replace the steering gear actuator. 7. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Page 10763 Maintain the sensor position. Do not turn the sensor. Remove the rear wheel position sensor (2) from the steering gear. Installation Procedure 1. Important: Make sure the O-ring (1) is installed. Install the rear wheel position sensor (2) to the steering gear. 2. Important: Be careful to maintain the position of the replacement sensor. Remove the pin retaining the position of the new sensor and immediately install the sensor to the steering gear. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear wheel position sensor retaining bolts. Apply LOCTITE 242 blue. ^ Tighten the bolts to 4 Nm (35 inch lbs.). 4. Install the rear wheel position sensor cover (4). 5. Connect the electrical connector (1). 6. Install the steering gear protection shield (1) and retaining bolts (3). ^ Tighten the steering gear protection shield retaining bolts to 180 Nm (132 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Page 10764 7. Lower the vehicle. 8. Perform a four wheel alignment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair Suspension Mode Switch: Service and Repair Electronic Suspension Ride Control Switch Replacement Removal Procedure 1. Remove the instrument panel trim bezel. 2. Remove the switch from the lower opening of the switch plate panel. 3. Disconnect the electrical connector. Installation Procedure 1. Connect the electrical connector. 2. Install the switch into the lower opening of the switch plate panel. 3. Install the instrument panel trim bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 10773 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair Center Link: Service and Repair Relay Rod Replacement ^ Tools Required J 24319-B Universal Steering Linkage Puller - J 29193 Steering Linkage Installer (12 mm) - J 29194 Steering Linkage Installer (14 mm) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine protection shield, if equipped. 3. Remove the steering damper from the relay rod, if equipped. Refer to Steering Damper Replacement. 4. Important: Use the proper tool in order to separate all the tie rod and the ball joints. Remove the tie rod ends (6). Refer to Tie Rod Replacement. 5. Remove the idler arm ball stud nut (10).Do not reuse the nut. 6. Remove the pitman arm nut (8).Do not reuse the nut. 7. Remove the relay rod from the idler arm ball stud using the J 24319-B. 8. Remove the relay rod from the pitman arm ball stud using the J 24319-B. 9. Remove the relay rod from the vehicle. 10. Inspect the threads on the tie rod ends for damage. 11. Inspect the ball stud threads for damage. 12. Inspect the ball stud seals for excessive damage. 13. Clean the threads on the ball studs. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair > Page 10778 1. Install the relay rod (9) to the vehicle. 2. Install the relay rod (9) to the pitman arm ball stud (2). 3. Install the relay rod (9) to the idler arm ball stud (1). 4. Ensure the seal is on the stud. 5. Install the J 29193 or the J 29194. 6. Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the steering linkage installer in order to seat the tapers. ^ Tighten the steering linkage installer to 54 Nm (40 ft. lbs.). 7. Remove the J 29193 or the J 29194. 8. Install the new pitman arm prevailing torque nut. 9. Install the new idler arm prevailing torque nut. ^ Tighten the nuts to 62 Nm (46 ft. lbs.). 10. Install the tie rod ends. Refer to Tie Rod Replacement. 11. Install the steering damper to the relay rod, if equipped. Refer to Steering Damper Replacement. 12. Install the engine protection shield, if equipped. 13. Lower the vehicle. 14. Check the wheel alignment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Rear Front Steering Knuckle: Service and Repair Rear Steering Knuckle Replacement ^ Tools required J 24319-B Universal Steering Linkage Puller Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the wheel hub and bearing. 4. Remove the upper ball joint. 5. Remove the lower ball joint. 6. Remove the outer tie rod retaining nut and bracket (2). 7. Disconnect the outer tie rod from the steering knuckle using the J 24319-B (1). 8. Remove the park brake cable retaining bolt (3) from the steering knuckle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Rear > Page 10783 9. Remove the steering knuckle (2) from the vehicle. Installation Procedure 1. Install the steering knuckle (2) to the vehicle. 2. Install the upper ball joint. 3. Install the lower ball joint. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake cable retaining bolt (3) to the steering knuckle. ^ Tighten the bolt to 65 Nm (48 ft. lbs.). 5. Install the wheel hub and bearing. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Rear > Page 10784 6. Install the outer tie rod retaining nut to the steering knuckle. ^ Tighten the nut to 55 Nm (40 ft. lbs.). 7. Install the outer tie rod retaining bracket (2). ^ Tighten the bracket to 65 Nm (48 ft. lbs.). 8. Install the tire and wheel. 9. Lower the vehicle. 10. Perform a four wheel alignment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Rear > Page 10785 Front Steering Knuckle: Service and Repair Front Steering Knuckle Replacement (4WD) ^ Tools Required ^ J 43631 Ball Joint Remover ^ J 45851 Ball Joint Separator Protector Adapters Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the wheel hub and bearing assembly. Refer to Wheel Hub, Bearing, and Seal Replacement (RWD) Wheel Hub, Bearing, and Seal Replacement (4WD). 4. Support the lower control arm with a suitable jack. 5. Disconnect the outer tie rod to the steering knuckle. Refer to Tie Rod Replacement in Steering Linkage (Non- Rack and Pinion). 6. Remove the brake hose bracket retaining bolt from the steering knuckle. 7. Remove the upper control arm retaining nut and separate the upper ball joint from the steering knuckle using the J 43631 and J 45851. 8. Remove the lower control arm retaining nut. Separate the lower ball joint from the steering knuckle using the J 43631 and J 45851. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Rear > Page 10786 9. Remove the steering knuckle. Installation Procedure 1. Clean all grease and contaminants from the tapered section and the threads of the upper ball joint, the lower ball joint, and the tie rod end. 2. Clean and inspect the taper holes and the mounting surfaces of the steering knuckle. If any of the tapered holes are elongated, out of round, or damaged, replace the steering knuckle. 3. Install the steering knuckle. 4. Notice: Refer to Fastener Notice in Service Precautions. Connect the lower ball joint to the steering knuckle and install the retaining nut. ^ Tighten the lower control arm retaining nut to 100 Nm (74 ft. lbs.). 5. Connect the upper ball joint to the steering knuckle and install the retaining nut. ^ Tighten the upper control arm retaining nut to 50 Nm (37 ft. lbs.). 6. Install the brake hose and the bracket retaining bolt to the steering knuckle ^ Tighten the bolt to 9 Nm (80 inch lbs.). 7. Connect the outer tie rod to the steering knuckle. Refer to Tie Rod Replacement in Steering Linkage (Non-Rack and Pinion). 8. Install the wheel hub and bearing assembly. Refer to Wheel Hub, Bearing, and Seal Replacement (RWD) Wheel Hub, Bearing, and Seal Replacement (4WD). 9. Install the tire and wheel. 10. Remove the lower control arm support. 11. Lower the vehicle. 12. Align the vehicle. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) in Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Rear > Page 10787 Wheel Alignment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Service and Repair Idler Arm: Service and Repair Idler Arm Replacement ^ Tools Required J 24319-B Universal Steering Linkage Puller - J 29193 Steering Linkage Installer (12 mm) - J 29194 Steering Linkage Installer (14 mm) Removal Procedure Notice: Do not attempt to free the ball stud by using a pickle fork or wedge type tool, because seal or bushing damage could result. Use the proper tool to separate all ball joints. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine protection shield, if equipped. 3. Remove the idler arm ball stud nut (10).Do not reuse the idler arm ball stud nut. 4. Remove the idler arm from the relay rod using the J 24319-B. 5. Remove the idler arm frame bolts (3) and the nuts (1). 6. Remove the idler arm (2) from the vehicle. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Service and Repair > Page 10791 1. Position the idler arm (2) on the frame. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the frame bolts (3) and the nuts (1) to the idler arm. ^ Tighten the frame bolts or nuts to 99 Nm (73 ft. lbs.). 3. Install the relay rod (9) to the idler arm ball stud (1). Ensure the seal is on the stud. 4. Use the J 29193 in order to seat the tapers. ^ Tighten the J 29193 or the J 29194 to 54 Nm (40 ft. lbs.) in order to seat the tapers. 5. Install the new idler arm ball stud prevailing torque nut to the idler arm ball stud. ^ Tighten the nut to 62 Nm (46 ft. lbs.). 6. Install the engine protection shield, if equipped. 7. Lower the vehicle. 8. Check the wheel alignment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical Service Bulletins > Steering/Suspension - Pitman Arm Shaft Seal Service Kit Pitman Arm: Technical Service Bulletins Steering/Suspension - Pitman Arm Shaft Seal Service Kit INFORMATION Bulletin No.: 10-02-33-001A Date: October 13, 2010 Subject: Information on Pitman Arm Shaft Seal Service Kit Models: 2004-2005 Buick Rainier 2000-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2000-2005 Chevrolet Blazer, S-10 2000-2011 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2000-2005 GMC Jimmy, Sonoma 2000-2011 GMC Savana, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2000-2004 Oldsmobile Bravada 2003-2009 HUMMER H2 with Recirculating Ball Steering Gears Supercede: This bulletin is being revised to update the model years and models involved. Please discard Corporate Bulletin Number 10-02-33-001 (Section 02 - Steering). Note Do not replace the entire steering gear for a pitman seal leak. Technicians have been replacing entire steering gears due to not being able to service just the leaking pitman shaft seal. The seal is serviced as a kit and is not called out separately in the catalog illustration. The seal package is cataloged in Group 06.855 as Seal Kit - GM Part Number 26002516 - Steering Gear Pitman Shaft, which includes the seal, washer, retaining ring and dust seal or G/M P/N 19256667, which includes the seal and retainer. Refer to Steering Gear Pitman Shaft Seal in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical Service Bulletins > Page 10796 Pitman Arm: Service and Repair Pitman Arm Replacement ^ Tools Required J 6632-01 Pitman Arm Puller - J 29107-A Pitman Arm Puller Removal Procedure 1. Raise and suitable support the vehicle. Refer to Vehicle Lifting. 2. Remove the power steering gear. Refer to Power Steering Gear Replacement (Rack and Pinion) Power Steering Gear Replacement (Non Rack and Pinion) in Power Steering System. 3. Install the power steering gear into a vise. 4. Remove the pitman arm nut and washer. 5. Remove the pitman arm from the pitman shaft using J 6632-01 or J 29107-A. Installation Procedure 1. Install the pitman arm to the power steering gear. 2. Notice: Refer to Fastener Notice in Service Precautions. Install a new pitman arm washer and nut. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical Service Bulletins > Page 10797 ^ Tighten the nut to 250 Nm (184 ft. lbs.). 3. Remove the power steering gear from the vise. 4. Install the power steering gear. Refer to Power Steering Gear Replacement (Rack and Pinion) Power Steering Gear Replacement (Non Rack and Pinion) in Power Steering System. 5. Lower the vehicle. 6. Check the wheel alignment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair Power Steering System Bleeding Important: - Use clean, new power steering fluid type only. See: Maintenance - Hoses touching the frame, body or engine may cause system noise. Verify that the hoses do not touch any other part of the vehicle. - Loose connections may not leak, but could allow air into the steering system. Verify that all hose connections are tight. - Power steering fluid level must be maintained throughout bleed procedure. 1. Fill pump reservoir with fluid to minimum system level, FULL COLD level, or middle of hash mark on cap stick fluid level indicator. Important: With hydro-boost only, the oil level will appear falsely high if the hydro-boost accumulator is not fully charged. Do not apply the brake pedal with the engine OFF. This will discharge the hydro-boost accumulator. 2. If equipped with hydro-boost, fully charge the hydro-boost accumulator using the following procedure: 2.1 Start the engine. 2.2 Firmly apply the brake pedal 10-15 times. 2.3 Turn the engine OFF. 3. Raise the vehicle until the front wheels are off the ground. 4. Key on engine OFF, turn the steering wheel from stop to stop 12 times. - Vehicle equipped with hydro-boost systems or longer length power steering hoses may require turns up to 15 to 20 stop to stops. 5. Verify power steering fluid level per operation specification. See: Power Steering Fluid 6. Start the engine. Rotate steering wheel from left to right. Check for sign of cavitation or fluid aeration (pump noise/whining). 7. Verify the fluid level. Repeat the bleed procedure, if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Power Steering ............................................................................................................................................................. 0.77 - 1.25 liters (0.81 - 1.32 quarts) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 10806 Power Steering Fluid: Fluid Type Specifications POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent POWER STEERING SYSTEM (PHT) Power Steering Fluid GM P/N 88901975 (Canadian P/N 88901976) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair Power Steering Fluid Reservoir: Service and Repair Power Steering Reservoir Replacement - Off Vehicle Disassembly Procedure 1. Drain the power steering fluid from the power steering pump. 2. Remove the pump mounting studs (2). 3. Remove the connector and fitting assembly (5). To remove the variable assist steering actuator (3) and retaining ring (4); refer to Power Steering Pump Flow Control Valve Actuator Replacement - On Vehicle. 4. Remove the O-ring seal (6) from the connector and fitting assembly (4). 5. If replacement is required, remove the control valve assembly and the flow control spring from the pump housing assembly; refer to Power Steering Pump Flow Control Valve Replacement - Off Vehicle (Regular). 6. Remove the reservoir assembly (1) from the pump housing assembly (2). 7. Remove the O-ring seals (1) (4). 8. Remove the magnet (3). 9. Clean the magnet (3). 10. Inspect the welch plug in the power steering pump housing (2). Do not remove. If the welch plug is deformed or dislodged, replace the power steering pump housing (2). Assembly Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Page 10810 1. Important: Use new O-ring seals when assembling the power steering pump assembly. Lubricate the O-ring seals (1) (4) with power steering fluid. 2. To install the control valve assembly and flow control spring to the pump housing assembly (2); refer to Power Steering Pump Flow Control Valve Replacement - Off Vehicle (Regular). 3. Install the O-ring seals (1) (4) to the pump housing assembly (2). 4. Install the magnet (3) to the pump housing assembly (2). 5. Connect the reservoir assembly (1) to the pump housing assembly (2). 6. Install the O-ring seal. 7. Install the connector and fitting assembly (5). To install the variable assist steering actuator (3) and retaining ring (4); refer to Power Steering Pump Flow Control Valve Actuator Replacement - On Vehicle. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the pump mounting studs (2) to the pump housing (1). ^ Tighten the pump mounting studs (2) to 58 Nm (43 ft. lbs.). ^ Tighten the connector and fitting assembly (5) to 75 Nm (55 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet Pipe/Hose (Rack and Pinion) Power Steering Gear Inlet Pipe/Hose Replacement (Rack and Pinion) Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Remove the power steering inlet hose (2) from the power steering pump (1). 2. Remove the power steering inlet hose (2) from the power steering gear (3). Installation Procedure 1. Connect the power steering inlet hose (2) to the power steering gear (3). 2. Notice: Refer to Fastener Notice in Service Precautions. Connect the power steering inlet hose (2) to the power steering pump (1). ^ Tighten the hose connections to 28 Nm (20 ft. lbs.). 3. Bleed the power steering system. Refer to Bleeding the Power Steering System. 4. Inspect all the hose connections for leaks. (With Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (With Hydroboost) Removal Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 10815 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the power steering gear inlet hose (1) from the brake booster. 3. Remove the power steering gear inlet hose from the power steering gear. 4. Remove the power steering gear inlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear inlet hose (1) to the brake booster (2). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear inlet hose to the power steering gear. ^ Tighten both power steering gear inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. (Without Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Without Hydroboost) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine protection shield. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 10816 3. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 4. Remove the power steering gear inlet hose (3) from the power steering pump (1). 5. Remove the power steering gear inlet hose from the power steering gear. 6. Remove the power steering gear inlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear inlet hose (3) to the power steering pump (1). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear inlet hose to the power steering gear. ^ Tighten both power steering gear inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Install the engine protection shield. 6. Lower the vehicle. 7. Bleed the power steering system. Refer to Bleeding the Power Steering System. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 10817 Power Steering Line/Hose: Service and Repair Power Steering Gear Outlet Pipe/Hose (Recirculating Ball) Power Steering Gear Outlet Pipe/Hose Replacement (Recirculating Ball) Removal Procedure 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the power steering gear outlet hose (3) from the steering gear (2). 3. Remove the clamp retaining the power steering gear outlet hose (3) to the power steering pump (1).Remove the power steering gear outlet hose from the power steering pump. 4. Remove the power steering gear outlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear outlet hose (3) to the power steering pump (1).Position the clamp at the end of the hose. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear outlet hose to the power steering gear. ^ Tighten the outlet hose fitting to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. (Rack and Pinion) Power Steering Gear Outlet Pipe/Hose Replacement (Rack and Pinion) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 10818 Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Remove the power steering outlet hose (4) from the power steering gear (3). 2. Remove the power steering outlet hose (4) from the power steering cooler (5). Installation Procedure 1. Connect the power steering outlet hose (4) to the power steering cooler (5). 2. Connect the power steering outlet hose (4) to the power steering gear (3). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Connect the power steering outlet hose (2) to the power steering pump (1). ^ Tighten both hose connections to 28 Nm (20 ft. lbs.). 4. Bleed the power steering system. Refer to Bleeding the Power Steering System. 5. Inspect all the hose connections for leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 10819 Power Steering Line/Hose: Service and Repair Power Brake Booster Inlet Hose Replacement Power Brake Booster Inlet Hose Replacement Removal Procedure 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the brake booster inlet hose (1) from the brake booster (2). 3. Remove the brake booster inlet hose from the power steering pump. 4. Remove the brake booster inlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the brake booster inlet hose (1) to the brake booster (2). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the brake booster inlet hose to the power steering pump. ^ Tighten the brake booster inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 10820 Power Steering Line/Hose: Service and Repair Power Brake Booster Outlet Hose Replacement Power Brake Booster Outlet Hose Replacement Removal Procedure 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the brake booster outlet hose (1) from the brake booster (2). 3. Remove the clamp retaining the brake booster outlet hose to the power steering pump. 4. Remove the brake booster outlet hose from the vehicle. Installation Procedure 1. Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. Route the hose in the same position the hose occupied prior to removal. 2. Install the brake booster outlet hose (1) to the brake booster (2).Position the clamp at the end of the hose. 3. Install the brake booster outlet hose to the power steering pump (4).Position the clamp at the end of the hose. 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 10821 Power Steering Line/Hose: Service and Repair (Rack and Pinion) Power Steering Gear Inlet Pipe/Hose Replacement (Rack and Pinion) Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 1. Remove the power steering inlet hose (2) from the power steering pump (1). 2. Remove the power steering inlet hose (2) from the power steering gear (3). Installation Procedure 1. Connect the power steering inlet hose (2) to the power steering gear (3). 2. Notice: Refer to Fastener Notice in Service Precautions. Connect the power steering inlet hose (2) to the power steering pump (1). ^ Tighten the hose connections to 28 Nm (20 ft. lbs.). 3. Bleed the power steering system. Refer to Bleeding the Power Steering System. 4. Inspect all the hose connections for leaks. (With Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (With Hydroboost) Removal Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 10822 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the power steering gear inlet hose (1) from the brake booster. 3. Remove the power steering gear inlet hose from the power steering gear. 4. Remove the power steering gear inlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear inlet hose (1) to the brake booster (2). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear inlet hose to the power steering gear. ^ Tighten both power steering gear inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. (Without Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Without Hydroboost) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the engine protection shield. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 10823 3. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 4. Remove the power steering gear inlet hose (3) from the power steering pump (1). 5. Remove the power steering gear inlet hose from the power steering gear. 6. Remove the power steering gear inlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear inlet hose (3) to the power steering pump (1). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear inlet hose to the power steering gear. ^ Tighten both power steering gear inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Install the engine protection shield. 6. Lower the vehicle. 7. Bleed the power steering system. Refer to Bleeding the Power Steering System. (Recirculating Ball) Power Steering Gear Outlet Pipe/Hose Replacement (Recirculating Ball) Removal Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 10824 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the power steering gear outlet hose (3) from the steering gear (2). 3. Remove the clamp retaining the power steering gear outlet hose (3) to the power steering pump (1).Remove the power steering gear outlet hose from the power steering pump. 4. Remove the power steering gear outlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the power steering gear outlet hose (3) to the power steering pump (1).Position the clamp at the end of the hose. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear outlet hose to the power steering gear. ^ Tighten the outlet hose fitting to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. (Rack and Pinion) Power Steering Gear Outlet Pipe/Hose Replacement (Rack and Pinion) Removal Procedure Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 10825 1. Remove the power steering outlet hose (4) from the power steering gear (3). 2. Remove the power steering outlet hose (4) from the power steering cooler (5). Installation Procedure 1. Connect the power steering outlet hose (4) to the power steering cooler (5). 2. Connect the power steering outlet hose (4) to the power steering gear (3). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Connect the power steering outlet hose (2) to the power steering pump (1). ^ Tighten both hose connections to 28 Nm (20 ft. lbs.). 4. Bleed the power steering system. Refer to Bleeding the Power Steering System. 5. Inspect all the hose connections for leaks. Power Brake Booster Inlet Hose Replacement Power Brake Booster Inlet Hose Replacement Removal Procedure 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 10826 2. Remove the brake booster inlet hose (1) from the brake booster (2). 3. Remove the brake booster inlet hose from the power steering pump. 4. Remove the brake booster inlet hose from the vehicle. Installation Procedure 1. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Route the hose in the same position the hose occupied prior to removal. 2. Install the brake booster inlet hose (1) to the brake booster (2). Hand tighten only. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the brake booster inlet hose to the power steering pump. ^ Tighten the brake booster inlet hose fittings to 28 Nm (20 ft. lbs.). 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. Power Brake Booster Outlet Hose Replacement Power Brake Booster Outlet Hose Replacement Removal Procedure 1. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Install a drain pan under the vehicle. 2. Remove the brake booster outlet hose (1) from the brake booster (2). 3. Remove the clamp retaining the brake booster outlet hose to the power steering pump. 4. Remove the brake booster outlet hose from the vehicle. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 10827 1. Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. Route the hose in the same position the hose occupied prior to removal. 2. Install the brake booster outlet hose (1) to the brake booster (2).Position the clamp at the end of the hose. 3. Install the brake booster outlet hose to the power steering pump (4).Position the clamp at the end of the hose. 4. Remove the drain pan from under the vehicle. 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. (Non Rack and Pinion) Power Steering Hose Assembly Replacement (Non Rack and Pinion) Removal Procedure 1. Disconnect the energy storage box before serving the vehicle. 2. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Remove the power steering gear inlet hose (4) from the brake booster. 4. Remove the power brake booster outlet hose (3) retaining clamp (2) to remove the power brake booster hose outlet hose from the brake booster. 5. Remove the power brake booster inlet hose (1) from the brake booster. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 10828 6. Remove the power steering gear inlet hose (4) from the power steering gear. 7. Remove the power brake booster outlet hose (2) retaining clamp (3) to remove the power brake booster outlet hose from the power steering pump. 8. Remove the power brake booster inlet hose from the power steering pump. 9. Remove the power steering hose assembly from the vehicle. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 10829 1. Install the gear inlet hose to the gear (4). Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Important: Following this sequence ensures correct routing and orientation. 2. Install the booster inlet hose to the pump. Important: Ensure that the hose contacts the power steering pump as shown. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 10830 3. Install the booster outlet hose to the power steering pump nipple (5) and retaining clamp. 4. Install the booster inlet hose (1) to the booster. 5. Install the gear inlet hose to the booster. ^ Tighten both power steering inlet hose fittings to 32 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the booster outlet hose (3) to the booster and install the retaining clamp (2). 7. Remove the drain pan from under the vehicle. 8. Bleed the power steering system. Refer to Bleeding the Power Steering System. 9. Connect the energy storage box after servicing the vehicle. (Rack and Pinion) Power Steering Hose Assembly Replacement (Rack and Pinion) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 10831 Removal Procedure 1. Disconnect the energy storage box before servicing the vehicle. 2. Install a drain pan under the vehicle. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. 3. Remove the power steering gear inlet hose (4) from the brake booster. 4. Remove the power brake booster outlet hose (3) retaining clamp (2) to remove the power brake booster hose outlet hose from the brake booster. 5. Remove the power brake booster inlet hose (1) from the brake booster. 6. Remove the power steering gear inlet hose (5) from the power steering gear. 7. Remove the power brake booster outlet hose (2) retaining clamp (3) to remove the power brake booster outlet hose from the power steering pump. 8. Remove the power brake booster inlet hose (5) from the power steering pump. 9. Remove the power steering hose assembly from the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 10832 Installation Procedure 1. Install the booster inlet hose to the pump. Notice: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. Important: Following this sequence ensures correct routing and orientation. Important: Ensure that the hose contacts the power steering pump as shown. 2. Install the gear inlet hose to the gear (5). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 10833 3. Install the booster outlet hose to the power steering pump nipple and retaining clamp (2). 4. Install the booster inlet hose (1) to the booster. 5. Install the gear inlet hose to the booster. ^ Tighten both power steering inlet hose fittings to 32 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the booster outlet hose (3) to the booster and install the retaining clamp (2). 7. Remove the drain pan from under the vehicle. 8. Bleed the power steering system. Refer to Bleeding the Power Steering System. 9. Connect the energy storage box before after servicing the vehicle. (Rack and Pinion) Power Steering Cooler Pipe/Hose Replacement (Rack and Pinion) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 10834 Removal Procedure 1. Remove the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. 2. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Remove the power steering outlet hose (4) from the power steering gear (3). 3. Remove the power steering inlet hose from the power steering pump (1). 4. Remove the bolts (2) retaining the cooler to the radiator support. 5. Remove the power steering cooler from the vehicle. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering cooler (1) to the vehicle. ^ Tighten the power steering cooler retaining bolts to 5 Nm (44 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 10835 2. Connect the power steering inlet hose to the power steering pump (5).Install the retaining clamp. 3. Connect the power steering outlet hose (4) to the power steering gear (3).Install the retaining clamp. 4. Bleed the power steering system. Refer to Bleeding the Power Steering System. 5. Inspect all the hose connections for leaks. 6. Install the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. (With Hydroboost) Power Steering Cooler Pipe/Hose Replacement (With Hydroboost) Removal Procedure 1. Remove the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. 2. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Place a drain pan under the vehicle. 3. Siphon the fluid from the reservoir to prevent excess spillage. 4. Remove the clamp retaining the power steering cooler inlet hose (3) to the power steering gear (2). 5. Remove the clamp retaining power steering cooler outlet hose (5) to the power steering pump (1). 6. Remove the bolts (2) retaining the power steering cooler from the radiator support. 7. Remove the power steering cooler from the vehicle. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 10836 1. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering cooler (1) to the radiator support. ^ Tighten the bolts retaining the power steering cooler to 5 Nm (44 inch lbs.). 2. Install the power steering cooler outlet hose (3) to the power steering pump (2). 3. Install the retaining clamp. 4. Install the power steering inlet hose (5) to the power steering gear (1). 5. Install the retaining clamp. 6. Fill and bleed the power steering system. Refer to Bleeding the Power Steering System. 7. Inspect all the hose connections for leaks. 8. Install the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. (Without Hydroboost) Power Steering Cooler Pipe/Hose Replacement (Without Hydroboost) Removal Procedure 1. Remove the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. 2. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Remove the clamp retaining the power steering outlet hose (3) from the power steering gear (4). 3. Remove the clamp retaining the power steering inlet hose from the power steering pump (5). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 10837 4. Remove the bolts (2) retaining the power steering cooler from the radiator support. 5. Remove the power steering cooler from the vehicle. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering cooler (1) to the vehicle. ^ Tighten the power steering cooler retaining bolts to 5 Nm (44 inch lbs.). 2. Connect the power steering outlet hose (3) to the power steering gear (4). 3. Install the retaining clamp. 4. Connect the power steering inlet hose to the power steering pump. 5. Install the retaining clamp. 6. Bleed the power steering system. Refer to Bleeding the Power Steering System. 7. Inspect all the hose connections for leaks. 8. Install the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. (Parallel Hybrid Truck) Power Steering Cooler Pipe/Hose Replacement (Parallel Hybrid Truck) Removal Procedure 1. Disconnect the energy storage box before servicing the vehicle. 2. Remove the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 10838 3. Notice: Refer to Power Steering Hose Disconnected Notice in Service Precautions. Place a drain pan under the vehicle. 4. Siphon the fluid from the reservoir to prevent excess spillage. 5. Remove the clamp retaining the power steering cooler inlet hose (3) to the power steering gear. 6. Remove the clamp retaining power steering cooler outlet hose (2) to the power steering pump (1). 7. Remove the bolts (2) retaining the power steering cooler from the radiator support. 8. Remove the power steering cooler from the vehicle. Installation Procedure 1. Notice: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Gear Inlet Pipe/Hose > Page 10839 Refer to Fastener Notice in Service Precautions. Install the power steering cooler (1) to the radiator support. ^ Tighten the bolts retaining the power steering cooler to 5 Nm (44 inch lbs.). 2. Install the power steering cooler outlet hose (2) to the power steering pump (1). 3. Install the retaining clamp. 4. Install the power steering inlet hose (3) to the power steering gear (1). 5. Install the retaining clamp. 6. Fill and bleed the power steering system. Refer to Bleeding the Power Steering System. 7. Inspect all the hose connections for leaks. 8. Install the front grille. Refer to Grille Replacement (GMC) Grille Replacement (Chevrolet) in Exterior Trim. 9. Connect the energy storage box after servicing the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > Steering - Power Steering Pump Replacement Tips Power Steering Motor: Technical Service Bulletins Steering - Power Steering Pump Replacement Tips INFORMATION Bulletin No.: 06-02-32-013B Date: August 07, 2009 Subject: Diagnostic Tips/Recommendations When Power Steering Pump Replacement is Necessary Models: 1997-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and update the information. Please discard Corporate Bulletin Number 06-02-32-013A (Section 02 - Steering). A recently completed analysis of returned power steering (PS) pumps that had been replaced for noise, no power assist, no or low pressure and leaking conditions has indicated a high number of "No Trouble Found" results. Corporate Bulletin Number 01-02-32-004 indicates that when attempting to repair a power steering concern, the steering system analyzer should be utilized to assist the technician in a successful diagnosis. Note- Saturn ASTRA does not utilize the Power Steering System Analyzer. In addition, extensive warranty analysis has shown that the following situations are all significant root causes of PS pump failures: - Improper pulley installation - Re-using the O-rings - Using fluid other than the OE-specified steering fluid - Failure to flush the PS system In order to help improve customer satisfaction and reduce comebacks, GM recommends the following tips for replacing a PS pump: 1. Low or no pressure from the PS pump may be the results of dirty or contaminated fluid, which could cause the pressure relief valve to stop functioning. Using the proper tools, flush and bleed the PS system. Any residual contaminants will result in pump failure. 2. When removing the pulley, use the proper special tools. Because the pulley alignment is critical, distorting the pulley may damage bearings on the new PS pump. Note Some new PS pumps may not include a new O-ring. Please refer to the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. 3. Be sure to use only the new O-rings included with the PS pump. The new reservoir O-ring must be lubricated with OE-specific PS fluid prior to installation. Also make sure that the control valve O-ring is in its exact groove position and is NOT covering the pressure bypass hole. 4. Bleed the PS system according to the procedures/recommendations in SI. Following these procedures and using the correct tools and fluids should help ensure that the new PS pump operates properly. Skipping steps may cost you time and trouble later. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Service and Repair > Off Vehicle Power Steering Pressure Control Valve: Service and Repair Off Vehicle Power Steering Pump Flow Control Valve Replacement - Off Vehicle (Regular) Disassembly Procedure 1. Drain the oil from the reservoir (1). 2. Remove the control valve assembly (3) from the pump housing (1). Make sure the flow control spring (4) does not fall out of the pump housing (1). 3. Remove the rectangular section seal (2) from the control valve assembly (3). Assembly Procedure 1. Install the flow control spring (4) if removed from the pump housing (1). 2. Lubricate the new rectangular section seal (2) with power steering fluid. 3. Install the rectangular section seal (2) onto the control valve assembly (3). 4. Install the control valve assembly (3). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Service and Repair > Off Vehicle > Page 10848 Power Steering Pressure Control Valve: Service and Repair On Vehicle Power Steering Pump Flow Control Valve Actuator Replacement - On Vehicle Disassembly Procedure 1. Remove the electrical connector from the variable assist steering actuator (1). 2. Remove pump assembly from the vehicle, if the variable assist steering actuator (1) is not accessible. 3. Remove the retaining ring (2) from the variable assist steering actuator (1). 4. Important: Note the orientation of the variable assist steering actuator discharge fitting. Remove the variable assist steering actuator (1). 5. Remove the O-ring seal from the variable assist steering actuator. Assembly Procedure 1. Important: Note the orientation of the variable assist steering actuator discharge fitting. Lubricate and install the new O-ring seal with power steering fluid. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the variable assist steering actuator (1) to the pump assembly. ^ Tighten the actuator to 62 Nm (46 ft. lbs.). 3. Install the negative battery cable. 4. Important: If a new variable assist steering actuator (1) is being installed, position the electrical connector before installing the retaining ring (2). Install the electrical connector to the variable assist steering actuator (1). 5. Install the retaining ring (2) to the variable assist steering actuator (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Recalls for Power Steering Pump: > NHTSA04V045000 > Feb > 04 > Recall 04V045000: Possible Hydro-Boost Defect Power Steering Pump: Recalls Recall 04V045000: Possible Hydro-Boost Defect DEFECT: Certain sport utility vehicles, pickup trucks, and passenger vans fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 135, "Passenger Car Brake Systems." Some of these vehicles were produced with an out-of-specification brake hydro-boost housing relief valve bore. Consequently, the valve O-ring seal may fracture. Steering efforts may be slightly increased while braking or parking. Under certain driving conditions, a fractured seal may also require an increase in the applied brake pedal effort to achieve the same vehicle deceleration. REMEDY: Dealers are to replace the hydro-boost relief valve. The manufacturer has reported that owner notification is expected to begin during the second quarter of 2004. Owners may contact Cadillac at 1-866-982-2339; Chevrolet at 1-800-630-2438; GMC at 1-866-996-9463; or Hummer at 1-866-486-6376. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > NHTSA04V045000 > Feb > 04 > Recall 04V045000: Possible Hydro-Boost Defect Power Steering Pump: All Technical Service Bulletins Recall 04V045000: Possible Hydro-Boost Defect DEFECT: Certain sport utility vehicles, pickup trucks, and passenger vans fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 135, "Passenger Car Brake Systems." Some of these vehicles were produced with an out-of-specification brake hydro-boost housing relief valve bore. Consequently, the valve O-ring seal may fracture. Steering efforts may be slightly increased while braking or parking. Under certain driving conditions, a fractured seal may also require an increase in the applied brake pedal effort to achieve the same vehicle deceleration. REMEDY: Dealers are to replace the hydro-boost relief valve. The manufacturer has reported that owner notification is expected to begin during the second quarter of 2004. Owners may contact Cadillac at 1-866-982-2339; Chevrolet at 1-800-630-2438; GMC at 1-866-996-9463; or Hummer at 1-866-486-6376. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Page 10862 Power Steering Pump: Diagrams Disassembled View Power Steering Pump Disassembled View (Regular) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley Power Steering Pump: Service and Repair Power Steering Pulley Power Steering Pulley Replacement ^ Tools Required J 25034-C Power Steering Pump Pulley Remover - J 25033-C Power Steering Pump Pulley Installer Removal Procedure 1. Remove the upper fan shroud. 2. Remove the drive belt. 3. Remove the power steering pump pulley using the J 25034-C. Installation Procedure 1. Place the power steering pump pulley on the end of the power steering pump shaft. 2. Install the power steering pump pulley using J 25033-C. 3. Ensure that the power steering pump pulley (1) is flush against the power steering pump shaft (2), with an allowable variance of 0.25 mm (0.010 inch). 4. Install the drive belt. 5. Install the upper fan shroud. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley > Page 10865 Power Steering Pump: Service and Repair Power Steering Pump Bracket Replacement Power Steering Pump Bracket Replacement Removal Procedure 1. Remove the power steering pump from the bracket (3). 2. Remove the positive battery junction block bracket retaining bolts (2) from the power steering pump bracket. 3. Remove the bolts retaining the power steering pump bracket (3) to the engine. 4. Remove the power steering pump bracket from the vehicle. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley > Page 10866 1. Install the power steering pump (3) bracket to the engine. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the power steering pump bracket retaining bolts. ^ Tighten the power steering pump bracket retaining bolts to 25 Nm (18 ft. lbs.). 3. Install the power steering pump to the bracket. 4. Install the positive battery junction block bracket retaining bolts (2) to the power steering pump bracket. ^ Tighten the battery junction block retaining bolts to 9 Nm (80 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley > Page 10867 Power Steering Pump: Service and Repair Power Steering Pump Replacement Power Steering Pump Replacement (6.6L Diesel) Removal Procedure 1. Place a drain pan under the vehicle. 2. Remove the power steering pulley. Refer to Power Steering Pulley Replacement. 3. Remove the bolt retaining the battery junction block from the power steering bracket. 4. Remove the bolts (1) from the rear of the pump. 5. Remove the bolts (2) from the front of the pump. 6. Remove the power steering pump mounting bracket retaining bolts to gain access to the power steering hoses. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley > Page 10868 7. Remove the power steering return hoses (2,4) from the power steering pump. 8. Remove the power steering pressure hose (2) from the power steering pump. 9. Remove the power steering pump from the vehicle. 10. Remove the rear bracket from the power steering pump. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Install the rear bracket to the power steering pump. ^ Tighten the rear bracket retaining nuts to 50 Nm (37 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley > Page 10869 2. Install the power steering return hoses and retaining clamps (3,5) to the power steering pump. 3. Install the power steering pressure hose (2) to the power steering pump. ^ Tighten the fitting to 28 Nm (20 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley > Page 10870 4. Install the bolts (1) to the rear of the power steering pump. ^ Tighten the rear bolts to 50 Nm (37 ft. lbs.). 5. Install the power steering pump mounting bracket and bolts. ^ Tighten the mounting bracket bolts to 46 Nm (34 ft. lbs.). 6. Install the bolts (2) to the front of the pump. ^ Tighten the power steering pump retaining bolts to 50 Nm (37 ft. lbs.). 7. Install the bolt retaining the battery junction block from the power steering bracket. ^ Tighten the battery junction block retaining bolt to 9 Nm (80 inch lbs.). 8. Install the power steering pulley. Refer to Power Steering Pulley Replacement. 9. Fill and bleed the power steering system. Refer to Bleeding the Power Steering System. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley > Page 10871 Power Steering Pump: Service and Repair Power Steering Pump Replacement (Parallel Hybrid Truck) Power Steering Pump Replacement (Parallel Hybrid Truck) Removal Procedure 1. Disconnect the energy storage box before servicing the vehicle. 2. Place a drain pan under the vehicle. 3. Disconnect the power steering pump pressure hose from the power steering pump. 4. Remove the clamps (2, 4) retaining the power steering return hoses (1, 5) to the power steering pump and remove the hoses. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley > Page 10872 5. Disconnect the upper electrical connector (3) from the power steering pump by pressing down on the rear of the locking tab and pulling the connector outward. 6. Disconnect the lower electrical connector (4) from the power steering pump by moving the locking lever over center and pulling the connector outward. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley > Page 10873 7. Remove the bolts (2) retaining the power steering pump to the bracket. 8. Remove the power steering pump from the vehicle. Installation Procedure 1. Install the power steering pump (1) to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the bolts retaining the power steering pump to the power steering pump bracket. ^ Tighten the power steering pump mounting bolts to 25 Nm (18 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley > Page 10874 3. Important: The lower connector will not go on if the upper connector is already installed. Connect the lower electrical connector (4) to the power steering pump. 4. Connect the upper electrical connector (3) to the power steering pump. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley > Page 10875 5. Install the power steering pump return hoses (1, 5) to the power steering pump. 6. Install the clamps retaining the power steering return hoses to the power steering pump. 7. Important: Ensure that the hose contacts the power steering pump as shown. Install the power steering pump pressure hose to the power steering pump. ^ Tighten the power steering pump pressure hose to 32 Nm (24 ft. lbs.). 8. Important: The power steering system on this vehicle does not use standard power steering fluid. Refer to Fluid and Lubricant Recommendations for the correct power steering fluid. Fill and bleed the power steering system. Refer to Bleeding the Power Steering System. 9. Clean up any spilled power steering fluid from the hoses, connectors or pump. 10. Connect the energy storage box after servicing the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley > Page 10876 11. Calibrate the brake pedal position sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley > Page 10877 Power Steering Pump: Service and Repair Power Steering Pump Wiring Harness Replacement Power Steering Pump Wiring Harness Replacement Removal Procedure 1. Disconnect the energy storage box before servicing the vehicle. 2. Remove the coolant surge tank to gain access to the electrical connectors. 3. Disconnect the electrical connectors (2) from the harness. 4. Remove the bolt retaining the wiring harness bracket (3) from the engine block. 5. Remove the electrical wiring harness clip (4) from the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley > Page 10878 6. Disconnect the electrical connector (3) from the power steering pump (4) by pressing downward on the rear of the locking tab and pulling the connector outward. 7. Remove the power steering pump wiring harness from the vehicle. Installation Procedure 1. Install the power steering wiring harness to the vehicle. 2. Connect the power steering pump wiring harness electrical connector (3) to the power steering pump (4). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley > Page 10879 3. Install the electrical wiring harness clip (4) to the bracket. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the bolt retaining the wiring harness bracket (3) to the engine block. ^ Tighten the bolt retaining the ground to the engine block to 9 Nm (80 inch lbs.). 5. Connect the electrical connectors (2) to the wiring harness. 6. Install the coolant surge tank to the vehicle. 7. Connect the energy storage box after servicing the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement Steering Control Module: Service and Repair Rear Wheel Steering Control Module Bracket Replacement Rear Wheel Steering Control Module Bracket Replacement Removal Procedure 1. Remove the rear wheel steering control module from the bracket. 2. Remove the bolts retaining the bracket (2) to the frame. 3. Remove the bracket (2) from the vehicle. Installation Procedure 1. Install the bracket (2) to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts retaining the bracket (2) to the frame. ^ Tighten the bracket retaining bolts to 10 Nm (81 inch lbs.). 3. Install the rear wheel steering control module to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement > Page 10884 Steering Control Module: Service and Repair Rear Wheel Steering Control Module Replacement Rear Wheel Steering Control Module Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the spare tire from the vehicle to gain access to the control module. 3. Disconnect the electrical connectors from the control module. 4. Remove the bolts (1) retaining the control module (2) to the bracket. 5. Remove the control module from the vehicle. Installation Procedure 1. Install the control module to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the control module (2) retaining bolts (1). ^ Tighten the bolts to 24 Nm (18 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement > Page 10885 3. Connect the electrical connectors to the module. 4. Program the control module. Refer to Service Programming System (SPS) in Programming. 5. Install the spare tire to the vehicle. 6. Lower the vehicle. 7. Perform a learn alignment. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Rear Wheel Steering > Rear Wheel Steering Actuator > Component Information > Service and Repair > Steering Gear Actuator Boot Shield Replacement Rear Wheel Steering Actuator: Service and Repair Steering Gear Actuator Boot Shield Replacement Steering Gear Actuator Boot Shield Replacement Removal Procedure 1. Notice: When lifting the vehicle do not allow the jack to touch the rear steering gear. If the jack touches the rear steering gear you may damage the gear or the rack and pinion boots. If the boots are damaged replace the rack and pinion boot. Raise the vehicle. Refer to Vehicle Lifting. 2. Unsnap the locking tabs on the rack and pinion boot protector (1). 3. Remove the rack and pinion boot protector (1) from the rack and pinion boot (2). Installation Procedure 1. Install the rack and pinion boot protector (1) to the rack and pinion boot (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Rear Wheel Steering > Rear Wheel Steering Actuator > Component Information > Service and Repair > Steering Gear Actuator Boot Shield Replacement > Page 10891 2. Snap the locking tabs together on the rack and pinion boot protector. 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Rear Wheel Steering > Rear Wheel Steering Actuator > Component Information > Service and Repair > Steering Gear Actuator Boot Shield Replacement > Page 10892 Rear Wheel Steering Actuator: Service and Repair Steering Gear Actuator and Cover Replacement Steering Gear Actuator and Cover Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the drain plug (2) and drain the fluid from the differential housing. 4. Remove the bolts (3) retaining the steering gear protection shield. 5. Disconnect the electrical connectors from the control module (2). 6. Disconnect the electrical connector (1) from the rear position sensor. 7. Remove the outer tie rod ends from the steering knuckle. Refer to Rear Wheel Steering Tie Rod End Replacement - Outer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Rear Wheel Steering > Rear Wheel Steering Actuator > Component Information > Service and Repair > Steering Gear Actuator Boot Shield Replacement > Page 10893 8. Disconnect the differential vent hose (1) from the vent tube (2). 9. Remove the bolts retaining the steering gear actuator and cover (2) to the differential (1). 10. Remove the steering gear actuator and cover from the vehicle. Installation Procedure 1. Important: Clean all of the sealing surfaces prior to installing the gasket. Do not reinstall the old gasket, replace the gasket whenever the actuator is removed from the axle. Install the steering gear actuator (2) and gasket (1) to the differential. 2. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Rear Wheel Steering > Rear Wheel Steering Actuator > Component Information > Service and Repair > Steering Gear Actuator Boot Shield Replacement > Page 10894 Install the steering gear actuator and cover (2) retaining bolts. ^ Tighten the bolts to 61 Nm (45 ft. lbs.). 3. Connect the electrical connectors to the control module (2). 4. Install the differential vent hose (1) to the vent tube (2). 5. Install the outer tie rod ends to the steering knuckle. Refer to Rear Wheel Steering Tie Rod End Replacement - Outer. 6. Install the drain plug (2) and fill the differential with fluid. 7. Install the bolts (3) retaining the steering gear protection shield. ^ Tighten the bolts to 180 Nm (132 ft. lbs.). 8. Install the tire and wheel. 9. Lower the vehicle. 10. Check the wheel alignment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Rear Wheel Steering > Rear Wheel Steering Switch > Component Information > Service and Repair Rear Wheel Steering Switch: Service and Repair Rear Wheel Steering Mode Switch Replacement Removal Procedure 1. Remove the dash trim bezel. 2. Grasp the rear wheel steering mode switch housing (2) and pull outward to remove the switch assembly. 3. Disconnect the electrical connector (3) from the rear wheel steering mode switch. 4. Remove the rear wheel steering mode switch assembly (1) from the vehicle. Installation Procedure 1. Reconnect the rear wheel steering mode switch (3) electrical connectors. 2. Install the rear wheel steering mode switch (1) into the dash. 3. Reinstall the dash trim bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement Steering Control Module: Service and Repair Rear Wheel Steering Control Module Bracket Replacement Rear Wheel Steering Control Module Bracket Replacement Removal Procedure 1. Remove the rear wheel steering control module from the bracket. 2. Remove the bolts retaining the bracket (2) to the frame. 3. Remove the bracket (2) from the vehicle. Installation Procedure 1. Install the bracket (2) to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts retaining the bracket (2) to the frame. ^ Tighten the bracket retaining bolts to 10 Nm (81 inch lbs.). 3. Install the rear wheel steering control module to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement > Page 10903 Steering Control Module: Service and Repair Rear Wheel Steering Control Module Replacement Rear Wheel Steering Control Module Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the spare tire from the vehicle to gain access to the control module. 3. Disconnect the electrical connectors from the control module. 4. Remove the bolts (1) retaining the control module (2) to the bracket. 5. Remove the control module from the vehicle. Installation Procedure 1. Install the control module to the vehicle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the control module (2) retaining bolts (1). ^ Tighten the bolts to 24 Nm (18 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Service and Repair > Rear Wheel Steering Control Module Bracket Replacement > Page 10904 3. Connect the electrical connectors to the module. 4. Program the control module. Refer to Service Programming System (SPS) in Programming. 5. Install the spare tire to the vehicle. 6. Lower the vehicle. 7. Perform a learn alignment. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Rear Wheel Steering Switch > Component Information > Service and Repair Rear Wheel Steering Switch: Service and Repair Rear Wheel Steering Mode Switch Replacement Removal Procedure 1. Remove the dash trim bezel. 2. Grasp the rear wheel steering mode switch housing (2) and pull outward to remove the switch assembly. 3. Disconnect the electrical connector (3) from the rear wheel steering mode switch. 4. Remove the rear wheel steering mode switch assembly (1) from the vehicle. Installation Procedure 1. Reconnect the rear wheel steering mode switch (3) electrical connectors. 2. Install the rear wheel steering mode switch (1) into the dash. 3. Reinstall the dash trim bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Rear Position Sensor Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the steering gear protection shield (1) retaining bolts (3). 3. Disconnect the electrical connector (1). 4. Notice: When removing the rear position cover from the steering gear be careful not to damage to the rear position sensor. Remove the rear wheel position sensor cover (4) from the steering gear by prying on the cover using the slot. 5. Remove the rear wheel position sensor retaining bolts (3). 6. Important: Check the inner tie rod boot for wear or damage. If the boots are damaged replace the steering gear actuator. 7. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Page 10912 Maintain the sensor position. Do not turn the sensor. Remove the rear wheel position sensor (2) from the steering gear. Installation Procedure 1. Important: Make sure the O-ring (1) is installed. Install the rear wheel position sensor (2) to the steering gear. 2. Important: Be careful to maintain the position of the replacement sensor. Remove the pin retaining the position of the new sensor and immediately install the sensor to the steering gear. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear wheel position sensor retaining bolts. Apply LOCTITE 242 blue. ^ Tighten the bolts to 4 Nm (35 inch lbs.). 4. Install the rear wheel position sensor cover (4). 5. Connect the electrical connector (1). 6. Install the steering gear protection shield (1) and retaining bolts (3). ^ Tighten the steering gear protection shield retaining bolts to 180 Nm (132 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Page 10913 7. Lower the vehicle. 8. Perform a four wheel alignment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Column Position Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement (Centering Required) ^ Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure 1. Set the front wheels in the straight-ahead position. 2. Install J 42640 or set the steering wheel in the LOCKED position. 3. Caution: Refer to SIR Caution in Service Precautions. Disconnect the negative battery cable. 4. Disable the SIR. 5. Important: You MUST make an alignment mark on the upper intermediate shaft to the steering column shaft, where they connect. You will need the alignment marks for installation. Make an alignment mark on the upper intermediate shaft and the steering column shaft, where they connect, before removal. 6. Remove the nut and the bolt from the upper to the lower steering shaft connection. Slide the lower shaft down. 7. Remove the steering wheel position sensor connector by using a suitable tool in order to pull the connector down around the right side of the steering column for accessibility. 8. Important: Do not apply force to the steering wheel position sensor and the adapter and bearing assembly in a sideways direction. If reusing the existing steering wheel position sensor, it MUST be centered before removal. Verify the type of steering wheel position sensor before removal. Refer to Steering Wheel Position Sensor Centering. 9. Remove the steering wheel position sensor and adapter and bearing assembly from the steering column jacket by pulling the assembly straight out. 10. Remove the steering wheel position sensor from the clips in the adapter and bearing assembly. Installation Procedure 1. Important: A new sensor MUST come with a pin installed. If pin is not installed, return and reorder sensor. Verify the following before installing the steering wheel position sensor: ^ The front wheels are in the straight-ahead position. ^ That J 42640 is installed or the steering wheel is in the LOCKED position. 2. If reusing the existing steering wheel position sensor, verify the type of sensor you have before installing. Refer to Steering Wheel Position Sensor Centering. 3. Install the steering wheel position sensor into the adapter and bearing assembly. 4. Install the adapter and bearing assembly into the steering column jacket. 1. Align the notches on the adapter and bearing assembly and the steering column jacket. 2. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10918 Do not apply force to the steering wheel position sensor and the adapter and bearing assembly in a sideways direction. Seat the adapter and bearing assembly into the steering column jacket. 5. Connect the steering wheel position sensor connector. 6. Notice: Refer to Fastener Notice in Service Precautions. Align the marks on the upper intermediate shaft and the steering column shafts, where they connect, that you made during the removal procedure. 7. Install the intermediate shaft to the steering column pinch bolt. ^ Tighten the nut to 62 Nm (46 ft. lbs.). 8. Connect the negative battery cable. 9. Enable the SIR system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10919 Steering Column Position Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure 1. Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. 3. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) 7. Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10920 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note location of the pin hole. ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin. Note the location of the pin hole. ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10921 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure 1. Important: If reusing the existing sensor, no centering of the sensor is required. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right.From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin. Note the location of the pin hole. ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10922 ^ A foam ring (3) ^ An alignment tab (2) for installing into the adapter and bearing assembly ^ A view of the inside of the connector 7. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin. Note location of the pin hole. ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 11. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 15. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10923 until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 19. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin. Note location of the pin hole. ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 23. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10924 Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10925 Steering Column Position Sensor: Service and Repair Inflatable Restraint Steering Wheel Module Coil Centering Inflatable Restraint Steering Wheel Module Coil Centering 1. Notice: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction. Important: If double wire harness strap is installed onto the wire harness assembly and column, you must reuse the holder for the wire straps during installation. Remove the wire harness strap(s) where necessary. Verify the following conditions before centering the SIR coil: ^ The wheels on the vehicle are straight ahead. ^ The block tooth (1) of the steering shaft assembly is in the 12 o'clock position. ^ The ignition switch is in the LOCK position. 2. If the front (5) of the SIR coil has a centering window (4), and the back side (2) includes a spring service lock (1), perform the following steps: 1. Hold the SIR coil with the face up. 2. While depressing the spring service lock, rotate the coil hub clockwise until the coil ribbon stops. 3. Rotate the coil hub slowly, counterclockwise, until the centering window appears yellow and both arrows (3) line up. 4. Release spring service lock between the locking tab. The SIR coil is now centered. 5. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 3. If the front (4) of the SIR coil has a centering window (3), and the back side (1) includes NO spring service lock, perform the following steps: 0. Hold the SIR coil with the face up. 1. Rotate the coil hub clockwise until the coil ribbon stops. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10926 2. Rotate the coil hub slowly, counterclockwise until the centering window appears yellow and both arrows (2) line up. This is the CENTER position. 3. While holding the coil hub in the CENTER position, align the SIR coil with the horn tower and slide onto the steering shaft assembly. 4. If the front side (3) of the SIR coil has NO centering window, but the back side (2) includes a spring service lock (1), perform the following steps: 0. Hold the SIR coil with the back side up. 1. While depressing the spring service lock, rotate the coil hub in the direction of the arrow (4) until the coil ribbon stops. 2. Still pressing the spring service lock, rotate the coil hub in the opposite direction 21⁄2 revolutions. 3. Release the spring service lock between locking tabs. The SIR coil is now centered. 4. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 5. If the front side (2) of the SIR coil has NO centering window, and the back side (1) includes NO spring service lock, perform the following steps: 0. Hold the SIR coil with the face up. 1. Rotate the coil hub in the direction of the arrow until the coil ribbon stops. 2. Rotate the coil hub, slowly, counterclockwise, for 21⁄2 revolutions. This is the CENTER position. 3. While maintaining the coil hub in the CENTER position, align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 6. If double wire harness strap is installed onto the wire harness assembly and column, you must route the wires up against the steering column. One wire harness strap will surround one lead from the coil to the steering column. The other wire harness strap will surround all leads to the steering column. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Rear Position Sensor Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the steering gear protection shield (1) retaining bolts (3). 3. Disconnect the electrical connector (1). 4. Notice: When removing the rear position cover from the steering gear be careful not to damage to the rear position sensor. Remove the rear wheel position sensor cover (4) from the steering gear by prying on the cover using the slot. 5. Remove the rear wheel position sensor retaining bolts (3). 6. Important: Check the inner tie rod boot for wear or damage. If the boots are damaged replace the steering gear actuator. 7. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Page 10930 Maintain the sensor position. Do not turn the sensor. Remove the rear wheel position sensor (2) from the steering gear. Installation Procedure 1. Important: Make sure the O-ring (1) is installed. Install the rear wheel position sensor (2) to the steering gear. 2. Important: Be careful to maintain the position of the replacement sensor. Remove the pin retaining the position of the new sensor and immediately install the sensor to the steering gear. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear wheel position sensor retaining bolts. Apply LOCTITE 242 blue. ^ Tighten the bolts to 4 Nm (35 inch lbs.). 4. Install the rear wheel position sensor cover (4). 5. Connect the electrical connector (1). 6. Install the steering gear protection shield (1) and retaining bolts (3). ^ Tighten the steering gear protection shield retaining bolts to 180 Nm (132 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Page 10931 7. Lower the vehicle. 8. Perform a four wheel alignment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling The SIR Identification Views shown below illustrate the approximate location of all SIR components available for the vehicle. This will assist in determining the appropriate SIR Disabling and Enabling for a given service procedure. Refer to See: Restraint Systems/Air Bag Systems/Locations/SIR Zone Identification Views There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: - Do not expose inflator modules to temperatures above 65°C (150°F). - Verify the correct replacement part number. Do not substitute a component from a different vehicle. - Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: - Inflatable restraint sensing and diagnostic module (SDM) - Any Inflatable restraint air bag module - Inflatable restraint steering wheel module coil - Any Inflatable restraint sensor - Inflatable restraint seat belt pretensioners - Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Important: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 10936 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Locations Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel Steering Column Bearing: Customer Interest Steering - Underhood Clunk Heard/Felt in Steering Wheel TECHNICAL Bulletin No.: 00-02-35-003N Date: March 26 2008 Subject: Clunking Noise Under Hood and Can Be Felt in Steering Wheel and/or Steering Column (Replace Upper Intermediate Steering Shaft [I-Shaft] Assembly) Models: 2002-2006 Cadillac Escalade Models 1999-2007 Chevrolet Silverado Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Models (Classic) 2000-2006 GMC Yukon, Yukon XL Models 2003-2006 HUMMER H2 Attention: This Service Bulletin DOES NOT include Mid-Size Utilities such as Buick Rainier, Chevrolet TrailBlazer Models, GMC Envoy Models or Oldsmobile Bravada. Refer to Service Bulletin 02-02-35-006A or newer for Mid-Size Utilities. Supercede: This bulletin is being revised to add diagnostic information (refer to Diagnostic Tips) to check the lower steering column bearing as a potential source of the noise. Please discard Corporate Bulletin Number 00-02-35-003M (Section 02-Steering). Condition Some customers may comment on a clunk-type noise coming from under the hood that also can be felt in the steering wheel. These conditions may be more noticeable when turning at low speeds on rough road surfaces. Diagnostic Tips Use the information below to help diagnose the source of the noise. ^ The lower steering column bearing may create the same noise as the intermediate shaft. Before replacing the I-shaft, verify the noise isn't being caused by movement from the lower steering column bearing. Check the bearing for movement by pushing up and down on the I-shaft where it attaches to the steering column. ^ Frame Snap and/or Popping Type Noise - A frame snap or popping type noise can be duplicated on rough or smooth road surfaces with steering wheel input to the left or the right. This type of noise can be HEARD and is typically louder with the windows rolled down. For additional information refer to Corporate Bulletin Number 03-08-61-002F or newer - Snap/Popping Type Noise Coming from Front of Vehicle (Remove Front Crossmember Change Fastener Orientation). ^ Intermediate Shaft Clunk - Intermediate shaft clunk is heard and FELT in the steering wheel and/or steering column area typically while driving on rough road surfaces with steering wheel input. Correction Important: ^ I-shaft P/N 19153614 has been designed to replace previous designed dampened and non-dampened I-shafts. The physical difference in the yoke size will accommodate all vehicles listed in this bulletin. ^ Due to the design of the new I-shaft, it is not possible to lubricate/grease the I-shaft. Replace the steering column upper intermediate shaft with an improved design shaft that will eliminate the clunk noise using the procedure listed below. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 10948 1. Set the front wheels in the straight ahead position. Notice: On the 2002 and later model year vehicles the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil. 2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles. 3. For 2002 and later vehicles install the J 42640 in the steering column lower access hole. 4. From under the hood remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft. 5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft. 6. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the carpet away from the accelerator pedal position (APP) sensor. 2. Remove the two nuts retaining the accelerator pedal to the bulkhead. 3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 10949 7. From inside the vehicle remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection. 8. Remove the upper intermediate steering shaft assembly. 1. From inside the vehicle slide the shaft down and off the steering column. 2. From inside the vehicle slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle. 9. Replace the upper intermediate shaft. 10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft. 11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft. 12. Install the upper bolt and nut. Tighten Tighten the bolt to 47 N.m (35 lb ft). 13. Install the lower bolt and nut. Tighten Tighten the bolt to 50 N.m (37 lb ft). 14. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the accelerator pedals into position on the bulkhead. 2. Install the two retaining nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Reposition the carpet into place. Parts Information Warranty Information For vehicles repaired under warranty use, the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Bearing: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 10950 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel Steering Column Bearing: All Technical Service Bulletins Steering - Underhood Clunk Heard/Felt in Steering Wheel TECHNICAL Bulletin No.: 00-02-35-003N Date: March 26 2008 Subject: Clunking Noise Under Hood and Can Be Felt in Steering Wheel and/or Steering Column (Replace Upper Intermediate Steering Shaft [I-Shaft] Assembly) Models: 2002-2006 Cadillac Escalade Models 1999-2007 Chevrolet Silverado Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Models (Classic) 2000-2006 GMC Yukon, Yukon XL Models 2003-2006 HUMMER H2 Attention: This Service Bulletin DOES NOT include Mid-Size Utilities such as Buick Rainier, Chevrolet TrailBlazer Models, GMC Envoy Models or Oldsmobile Bravada. Refer to Service Bulletin 02-02-35-006A or newer for Mid-Size Utilities. Supercede: This bulletin is being revised to add diagnostic information (refer to Diagnostic Tips) to check the lower steering column bearing as a potential source of the noise. Please discard Corporate Bulletin Number 00-02-35-003M (Section 02-Steering). Condition Some customers may comment on a clunk-type noise coming from under the hood that also can be felt in the steering wheel. These conditions may be more noticeable when turning at low speeds on rough road surfaces. Diagnostic Tips Use the information below to help diagnose the source of the noise. ^ The lower steering column bearing may create the same noise as the intermediate shaft. Before replacing the I-shaft, verify the noise isn't being caused by movement from the lower steering column bearing. Check the bearing for movement by pushing up and down on the I-shaft where it attaches to the steering column. ^ Frame Snap and/or Popping Type Noise - A frame snap or popping type noise can be duplicated on rough or smooth road surfaces with steering wheel input to the left or the right. This type of noise can be HEARD and is typically louder with the windows rolled down. For additional information refer to Corporate Bulletin Number 03-08-61-002F or newer - Snap/Popping Type Noise Coming from Front of Vehicle (Remove Front Crossmember Change Fastener Orientation). ^ Intermediate Shaft Clunk - Intermediate shaft clunk is heard and FELT in the steering wheel and/or steering column area typically while driving on rough road surfaces with steering wheel input. Correction Important: ^ I-shaft P/N 19153614 has been designed to replace previous designed dampened and non-dampened I-shafts. The physical difference in the yoke size will accommodate all vehicles listed in this bulletin. ^ Due to the design of the new I-shaft, it is not possible to lubricate/grease the I-shaft. Replace the steering column upper intermediate shaft with an improved design shaft that will eliminate the clunk noise using the procedure listed below. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 10956 1. Set the front wheels in the straight ahead position. Notice: On the 2002 and later model year vehicles the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil. 2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles. 3. For 2002 and later vehicles install the J 42640 in the steering column lower access hole. 4. From under the hood remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft. 5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft. 6. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the carpet away from the accelerator pedal position (APP) sensor. 2. Remove the two nuts retaining the accelerator pedal to the bulkhead. 3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 10957 7. From inside the vehicle remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection. 8. Remove the upper intermediate steering shaft assembly. 1. From inside the vehicle slide the shaft down and off the steering column. 2. From inside the vehicle slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle. 9. Replace the upper intermediate shaft. 10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft. 11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft. 12. Install the upper bolt and nut. Tighten Tighten the bolt to 47 N.m (35 lb ft). 13. Install the lower bolt and nut. Tighten Tighten the bolt to 50 N.m (37 lb ft). 14. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the accelerator pedals into position on the bulkhead. 2. Install the two retaining nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Reposition the carpet into place. Parts Information Warranty Information For vehicles repaired under warranty use, the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Bearing: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 10958 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Column Position Sensor: Service and Repair Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement (Centering Required) ^ Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure 1. Set the front wheels in the straight-ahead position. 2. Install J 42640 or set the steering wheel in the LOCKED position. 3. Caution: Refer to SIR Caution in Service Precautions. Disconnect the negative battery cable. 4. Disable the SIR. 5. Important: You MUST make an alignment mark on the upper intermediate shaft to the steering column shaft, where they connect. You will need the alignment marks for installation. Make an alignment mark on the upper intermediate shaft and the steering column shaft, where they connect, before removal. 6. Remove the nut and the bolt from the upper to the lower steering shaft connection. Slide the lower shaft down. 7. Remove the steering wheel position sensor connector by using a suitable tool in order to pull the connector down around the right side of the steering column for accessibility. 8. Important: Do not apply force to the steering wheel position sensor and the adapter and bearing assembly in a sideways direction. If reusing the existing steering wheel position sensor, it MUST be centered before removal. Verify the type of steering wheel position sensor before removal. Refer to Steering Wheel Position Sensor Centering. 9. Remove the steering wheel position sensor and adapter and bearing assembly from the steering column jacket by pulling the assembly straight out. 10. Remove the steering wheel position sensor from the clips in the adapter and bearing assembly. Installation Procedure 1. Important: A new sensor MUST come with a pin installed. If pin is not installed, return and reorder sensor. Verify the following before installing the steering wheel position sensor: ^ The front wheels are in the straight-ahead position. ^ That J 42640 is installed or the steering wheel is in the LOCKED position. 2. If reusing the existing steering wheel position sensor, verify the type of sensor you have before installing. Refer to Steering Wheel Position Sensor Centering. 3. Install the steering wheel position sensor into the adapter and bearing assembly. 4. Install the adapter and bearing assembly into the steering column jacket. 1. Align the notches on the adapter and bearing assembly and the steering column jacket. 2. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10963 Do not apply force to the steering wheel position sensor and the adapter and bearing assembly in a sideways direction. Seat the adapter and bearing assembly into the steering column jacket. 5. Connect the steering wheel position sensor connector. 6. Notice: Refer to Fastener Notice in Service Precautions. Align the marks on the upper intermediate shaft and the steering column shafts, where they connect, that you made during the removal procedure. 7. Install the intermediate shaft to the steering column pinch bolt. ^ Tighten the nut to 62 Nm (46 ft. lbs.). 8. Connect the negative battery cable. 9. Enable the SIR system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10964 Steering Column Position Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure 1. Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. 3. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (2) ^ A pin hole (1) for centering the pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) 7. Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10965 11. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: ^ A raised rotor flange cuff (3) ^ An alignment mark (2) on the rotor flange cuff (3) for installation ^ A pin hole (1) for the centering pin. Note location of the pin hole. ^ A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (3) ^ A pin hole (1) for the centering pin. Note the location of the pin hole. ^ An alignment mark (2) on the flush rotor flange cuff (3) for installation 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10966 24. From the technicians point of view, the FRONT of the sensor will have: ^ A flush rotor flange cuff (4) ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ An alignment mark (3) on the flush rotor flange cuff (4) for installation ^ A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure 1. Important: If reusing the existing sensor, no centering of the sensor is required. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right.From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: ^ A foam ring (4) ^ A pin hole (7) for the centering pin. Note the location of the pin hole. ^ A flushed rotor flange cuff (6) ^ An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10967 ^ A foam ring (3) ^ An alignment tab (2) for installing into the adapter and bearing assembly ^ A view of the inside of the connector 7. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin. Note location of the pin hole. ^ A raised rotor flange cuff (5) ^ An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 11. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. 13. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ A raised rotor flange cuff (4) ^ An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 15. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10968 until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (2) for the centering pin. Note the location of the pin hole. ^ A flush rotor flange cuff (4) ^ An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. 19. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. 21. From the technicians point of view, the FRONT of the sensor will have: ^ A pin hole (3) for the centering pin. Note location of the pin hole. ^ A flush rotor flange cuff (5) ^ An alignment mark (4) for installation ^ A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: ^ Double D flats (1) ^ An alignment tab (2) for installing into the adapter and bearing assembly 23. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10969 Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10970 Steering Column Position Sensor: Service and Repair Inflatable Restraint Steering Wheel Module Coil Centering Inflatable Restraint Steering Wheel Module Coil Centering 1. Notice: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction. Important: If double wire harness strap is installed onto the wire harness assembly and column, you must reuse the holder for the wire straps during installation. Remove the wire harness strap(s) where necessary. Verify the following conditions before centering the SIR coil: ^ The wheels on the vehicle are straight ahead. ^ The block tooth (1) of the steering shaft assembly is in the 12 o'clock position. ^ The ignition switch is in the LOCK position. 2. If the front (5) of the SIR coil has a centering window (4), and the back side (2) includes a spring service lock (1), perform the following steps: 1. Hold the SIR coil with the face up. 2. While depressing the spring service lock, rotate the coil hub clockwise until the coil ribbon stops. 3. Rotate the coil hub slowly, counterclockwise, until the centering window appears yellow and both arrows (3) line up. 4. Release spring service lock between the locking tab. The SIR coil is now centered. 5. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 3. If the front (4) of the SIR coil has a centering window (3), and the back side (1) includes NO spring service lock, perform the following steps: 0. Hold the SIR coil with the face up. 1. Rotate the coil hub clockwise until the coil ribbon stops. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Position Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement > Page 10971 2. Rotate the coil hub slowly, counterclockwise until the centering window appears yellow and both arrows (2) line up. This is the CENTER position. 3. While holding the coil hub in the CENTER position, align the SIR coil with the horn tower and slide onto the steering shaft assembly. 4. If the front side (3) of the SIR coil has NO centering window, but the back side (2) includes a spring service lock (1), perform the following steps: 0. Hold the SIR coil with the back side up. 1. While depressing the spring service lock, rotate the coil hub in the direction of the arrow (4) until the coil ribbon stops. 2. Still pressing the spring service lock, rotate the coil hub in the opposite direction 21⁄2 revolutions. 3. Release the spring service lock between locking tabs. The SIR coil is now centered. 4. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 5. If the front side (2) of the SIR coil has NO centering window, and the back side (1) includes NO spring service lock, perform the following steps: 0. Hold the SIR coil with the face up. 1. Rotate the coil hub in the direction of the arrow until the coil ribbon stops. 2. Rotate the coil hub, slowly, counterclockwise, for 21⁄2 revolutions. This is the CENTER position. 3. While maintaining the coil hub in the CENTER position, align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 6. If double wire harness strap is installed onto the wire harness assembly and column, you must route the wires up against the steering column. One wire harness strap will surround one lead from the coil to the steering column. The other wire harness strap will surround all leads to the steering column. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Service and Repair Steering Damper: Service and Repair Steering Damper Replacement ^ Tools Required J 24319-B Universal Steering Linkage Puller - J 29193 Steering Linkage Installer-12 mm Removal Procedure 1. Raise the vehicle. Support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the engine protection shield, if equipped. 3. Important: Do not reuse the nut. Remove the steering damper (2) ball stud nut (1). 4. Remove the steering damper ball stud from the relay rod using the J 24319-B. 5. Important: Do not reuse the nut. Remove the steering damper mounting bolt (5) and the nut (6). 6. Remove the steering damper (4) from the vehicle. 7. Inspect the following parts: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Service and Repair > Page 10975 ^ The steering damper for leaks and damage ^ The mounting bolts and the nuts for damage or corrosion Installation Procedure 1. Install the steering damper (4). 2. Install the mounting bolt (5) and a new prevailing torque nut (6). 3. Install the steering damper ball stud (2) to the relay rod (3). 4. Notice: Refer to Fastener Notice in Service Precautions. Install the J 29193. 5. Tighten the steering linkage installer in order to seat the ball stud in the relay rod. ^ Tighten the installer to 54 Nm (40 ft. lbs.). 6. Remove the J 29193. 7. Install the prevailing torque nuts. ^ Tighten the steering damper mounting nut to 40 Nm (30 ft. lbs.). ^ Tighten the ball stud nut to 40 Nm (30 ft. lbs.). 8. Install the engine protection shield, if equipped. 9. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Technical Service Bulletins > Steering/Suspension - Pitman Arm Shaft Seal Service Kit Steering Gear Seal: Technical Service Bulletins Steering/Suspension - Pitman Arm Shaft Seal Service Kit INFORMATION Bulletin No.: 10-02-33-001A Date: October 13, 2010 Subject: Information on Pitman Arm Shaft Seal Service Kit Models: 2004-2005 Buick Rainier 2000-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2000-2005 Chevrolet Blazer, S-10 2000-2011 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2000-2005 GMC Jimmy, Sonoma 2000-2011 GMC Savana, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2000-2004 Oldsmobile Bravada 2003-2009 HUMMER H2 with Recirculating Ball Steering Gears Supercede: This bulletin is being revised to update the model years and models involved. Please discard Corporate Bulletin Number 10-02-33-001 (Section 02 - Steering). Note Do not replace the entire steering gear for a pitman seal leak. Technicians have been replacing entire steering gears due to not being able to service just the leaking pitman shaft seal. The seal is serviced as a kit and is not called out separately in the catalog illustration. The seal package is cataloged in Group 06.855 as Seal Kit - GM Part Number 26002516 - Steering Gear Pitman Shaft, which includes the seal, washer, retaining ring and dust seal or G/M P/N 19256667, which includes the seal and retainer. Refer to Steering Gear Pitman Shaft Seal in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Technical Service Bulletins > Page 10981 Steering Gear Seal: Service and Repair Steering Gear Stub Shaft Seals and Bearing Replacement - Off Vehicle ^ Tools Required J 29810 Stub Shaft Seal Protector Disassembly Procedure 1. Remove the steering gear from the vehicle, 2. Remove the adjuster plug lock nut (5) from the adjuster plug (4). 3. Remove the adjuster plug (4) from the gear assembly (1). 4. Remove the adjuster spring (3) and the rack bearing (2). 5. Remove the spool shaft boot (1) from the rack and pinion gear assembly. 6. Remove the retaining ring (2) from the valve bore of the rack and pinion gear assembly. 7. Remove the dust cover (4) from the bottom of the rack and pinion gear assembly. 8. Remove the hex lock nut (3) from the lower end of the pinion and valve assembly while holding the stub shaft with a 14 mm crowfoot wrench. 9. Using an arbor press (1), press on the threaded end of the pinion until removal of the following items is possible: 1. The stub shaft (4) 2. The stub shaft seal (2) 3. The stub shaft bearing annulus assembly (3) Important: When performing the following procedure, do not remove pinion and valve assembly from the rack and pinion gear assembly (5). Press the pinion and valve assembly only far enough to allow removal of the stub shaft bearing annulus (3) and the stub shaft seal (2). Assembly Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Technical Service Bulletins > Page 10982 1. Install the hex lock nut (1) onto the pinion while holding the valve stub shaft. ^ Tighten the nut to 30 Nm (22 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the dust cover (2) to the rack and pinion gear assembly. 3. Install the stub shaft bearing annulus assembly (1) onto the valve stub shaft (2). 4. Install J 29810 onto the valve stub shaft. 5. Lubricate the stub shaft seal (3) with grease. 6. Install the stub shaft seal (3) into the rack and pinion gear assembly. 7. Install the retaining ring (2) into the groove in the rack and pinion gear assembly. 8. Install the spool shaft boot (1) onto the rack and pinion gear assembly. 9. Lubricate the following items with lithium base grease: 1. The rack bearing (2) 2. The adjuster spring (3) 3. The adjuster plug (4) 10. Install the following items into the gear assembly: 1. The rack bearing (2) 2. The adjuster spring (3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Technical Service Bulletins > Page 10983 3. The adjuster plug (4) 11. Turn the adjuster plug (1) clockwise onto the rack and pinion gear assembly until the adjuster plug (1) bottoms in the rack and pinion gear assembly, then turn the adjuster plug (1) back 50 degrees to 70 degrees. 12. Check the rotational torque on the pinion. The maximum pinion preload torque is 1.8 Nm (16 inch lbs.). 13. Install the adjuster plug lock nut (5) to the adjuster plug (4).Finger tighten the adjuster plug lock nut (5) while holding the adjuster plug (4) stationary. ^ Tighten the nut to 68 Nm (50 ft. lbs.). 14. Install the steering gear into the vehicle, 15. Flush and bleed power the steering system (hoses, reservoir and cooler lines) with power steering fluid GM P/N 1050017 (Canadian P/N 992646) (or equivalent meeting GM Specification number 9985010). Important: Refer to Bleeding the Power Steering System. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions Steering Mounted Controls Transmitter: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10988 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10989 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10990 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10991 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10992 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10993 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10994 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10995 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10996 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10997 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10998 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 10999 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11000 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11001 Steering Mounted Controls Transmitter: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11002 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11003 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11004 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11005 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11006 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11007 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11008 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11009 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11010 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11011 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11012 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11013 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11014 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11015 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11016 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11017 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11018 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11019 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11020 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11021 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11022 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11023 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11024 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11025 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11026 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11027 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11028 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11029 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11030 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11031 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11032 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11033 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11034 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11035 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11036 Steering Mounted Controls Transmitter: Connector Views Steering Wheel Driver Information Center (DIC) Controls - Left (With RPO Code YE9) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11037 Steering Wheel Driver Information Center (DIC) Controls - Right (With RPO Code YE9) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 11038 Steering Mounted Controls Transmitter: Electrical Diagrams Steering Wheel Controls Diagram Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Page 11039 Steering Mounted Controls Transmitter: Service and Repair Steering Wheel Control Switch Assembly Replacement Removal Procedure 1. Remove the steering wheel. 2. Remove the shroud retaining screws from the back of the steering wheel. 3. Remove the shroud from the steering wheel. 4. Position a blunt ended tool into the wire harness cavity (1) and apply moderate pressure in order to partially remove the steering wheel control switch from the steering wheel. 5. Disconnect the steering wheel control switch electrical connector. 6. Important: The bulbs in the steering wheel control switches are not serviceable. The switches should be replaced only as an assembly. Remove the steering wheel control switch from the steering wheel. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Page 11040 1. Position the steering wheel control switch to the steering wheel. 2. Connect the electrical connector to the steering wheel control switch. 3. Install the steering wheel control switch into the steering wheel, ensuring the retaining tabs are fully seated. 4. Install the shroud to the steering wheel. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the shroud retaining screws to the steering wheel. ^ Tighten the screws to 2 Nm (18 inch lbs.). 6. Install the steering wheel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel Steering Shaft: Customer Interest Steering - Underhood Clunk Heard/Felt in Steering Wheel TECHNICAL Bulletin No.: 00-02-35-003N Date: March 26 2008 Subject: Clunking Noise Under Hood and Can Be Felt in Steering Wheel and/or Steering Column (Replace Upper Intermediate Steering Shaft [I-Shaft] Assembly) Models: 2002-2006 Cadillac Escalade Models 1999-2007 Chevrolet Silverado Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Models (Classic) 2000-2006 GMC Yukon, Yukon XL Models 2003-2006 HUMMER H2 Attention: This Service Bulletin DOES NOT include Mid-Size Utilities such as Buick Rainier, Chevrolet TrailBlazer Models, GMC Envoy Models or Oldsmobile Bravada. Refer to Service Bulletin 02-02-35-006A or newer for Mid-Size Utilities. Supercede: This bulletin is being revised to add diagnostic information (refer to Diagnostic Tips) to check the lower steering column bearing as a potential source of the noise. Please discard Corporate Bulletin Number 00-02-35-003M (Section 02-Steering). Condition Some customers may comment on a clunk-type noise coming from under the hood that also can be felt in the steering wheel. These conditions may be more noticeable when turning at low speeds on rough road surfaces. Diagnostic Tips Use the information below to help diagnose the source of the noise. ^ The lower steering column bearing may create the same noise as the intermediate shaft. Before replacing the I-shaft, verify the noise isn't being caused by movement from the lower steering column bearing. Check the bearing for movement by pushing up and down on the I-shaft where it attaches to the steering column. ^ Frame Snap and/or Popping Type Noise - A frame snap or popping type noise can be duplicated on rough or smooth road surfaces with steering wheel input to the left or the right. This type of noise can be HEARD and is typically louder with the windows rolled down. For additional information refer to Corporate Bulletin Number 03-08-61-002F or newer - Snap/Popping Type Noise Coming from Front of Vehicle (Remove Front Crossmember Change Fastener Orientation). ^ Intermediate Shaft Clunk - Intermediate shaft clunk is heard and FELT in the steering wheel and/or steering column area typically while driving on rough road surfaces with steering wheel input. Correction Important: ^ I-shaft P/N 19153614 has been designed to replace previous designed dampened and non-dampened I-shafts. The physical difference in the yoke size will accommodate all vehicles listed in this bulletin. ^ Due to the design of the new I-shaft, it is not possible to lubricate/grease the I-shaft. Replace the steering column upper intermediate shaft with an improved design shaft that will eliminate the clunk noise using the procedure listed below. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 11049 1. Set the front wheels in the straight ahead position. Notice: On the 2002 and later model year vehicles the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil. 2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles. 3. For 2002 and later vehicles install the J 42640 in the steering column lower access hole. 4. From under the hood remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft. 5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft. 6. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the carpet away from the accelerator pedal position (APP) sensor. 2. Remove the two nuts retaining the accelerator pedal to the bulkhead. 3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 11050 7. From inside the vehicle remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection. 8. Remove the upper intermediate steering shaft assembly. 1. From inside the vehicle slide the shaft down and off the steering column. 2. From inside the vehicle slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle. 9. Replace the upper intermediate shaft. 10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft. 11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft. 12. Install the upper bolt and nut. Tighten Tighten the bolt to 47 N.m (35 lb ft). 13. Install the lower bolt and nut. Tighten Tighten the bolt to 50 N.m (37 lb ft). 14. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the accelerator pedals into position on the bulkhead. 2. Install the two retaining nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Reposition the carpet into place. Parts Information Warranty Information For vehicles repaired under warranty use, the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 11051 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel Steering Shaft: All Technical Service Bulletins Steering - Underhood Clunk Heard/Felt in Steering Wheel TECHNICAL Bulletin No.: 00-02-35-003N Date: March 26 2008 Subject: Clunking Noise Under Hood and Can Be Felt in Steering Wheel and/or Steering Column (Replace Upper Intermediate Steering Shaft [I-Shaft] Assembly) Models: 2002-2006 Cadillac Escalade Models 1999-2007 Chevrolet Silverado Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Models (Classic) 2000-2006 GMC Yukon, Yukon XL Models 2003-2006 HUMMER H2 Attention: This Service Bulletin DOES NOT include Mid-Size Utilities such as Buick Rainier, Chevrolet TrailBlazer Models, GMC Envoy Models or Oldsmobile Bravada. Refer to Service Bulletin 02-02-35-006A or newer for Mid-Size Utilities. Supercede: This bulletin is being revised to add diagnostic information (refer to Diagnostic Tips) to check the lower steering column bearing as a potential source of the noise. Please discard Corporate Bulletin Number 00-02-35-003M (Section 02-Steering). Condition Some customers may comment on a clunk-type noise coming from under the hood that also can be felt in the steering wheel. These conditions may be more noticeable when turning at low speeds on rough road surfaces. Diagnostic Tips Use the information below to help diagnose the source of the noise. ^ The lower steering column bearing may create the same noise as the intermediate shaft. Before replacing the I-shaft, verify the noise isn't being caused by movement from the lower steering column bearing. Check the bearing for movement by pushing up and down on the I-shaft where it attaches to the steering column. ^ Frame Snap and/or Popping Type Noise - A frame snap or popping type noise can be duplicated on rough or smooth road surfaces with steering wheel input to the left or the right. This type of noise can be HEARD and is typically louder with the windows rolled down. For additional information refer to Corporate Bulletin Number 03-08-61-002F or newer - Snap/Popping Type Noise Coming from Front of Vehicle (Remove Front Crossmember Change Fastener Orientation). ^ Intermediate Shaft Clunk - Intermediate shaft clunk is heard and FELT in the steering wheel and/or steering column area typically while driving on rough road surfaces with steering wheel input. Correction Important: ^ I-shaft P/N 19153614 has been designed to replace previous designed dampened and non-dampened I-shafts. The physical difference in the yoke size will accommodate all vehicles listed in this bulletin. ^ Due to the design of the new I-shaft, it is not possible to lubricate/grease the I-shaft. Replace the steering column upper intermediate shaft with an improved design shaft that will eliminate the clunk noise using the procedure listed below. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 11057 1. Set the front wheels in the straight ahead position. Notice: On the 2002 and later model year vehicles the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil. 2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles. 3. For 2002 and later vehicles install the J 42640 in the steering column lower access hole. 4. From under the hood remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft. 5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft. 6. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the carpet away from the accelerator pedal position (APP) sensor. 2. Remove the two nuts retaining the accelerator pedal to the bulkhead. 3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 11058 7. From inside the vehicle remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection. 8. Remove the upper intermediate steering shaft assembly. 1. From inside the vehicle slide the shaft down and off the steering column. 2. From inside the vehicle slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle. 9. Replace the upper intermediate shaft. 10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft. 11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft. 12. Install the upper bolt and nut. Tighten Tighten the bolt to 47 N.m (35 lb ft). 13. Install the lower bolt and nut. Tighten Tighten the bolt to 50 N.m (37 lb ft). 14. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the accelerator pedals into position on the bulkhead. 2. Install the two retaining nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Reposition the carpet into place. Parts Information Warranty Information For vehicles repaired under warranty use, the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 11059 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Intermediate Steering Shaft Replacement - Upper Steering Shaft: Service and Repair Intermediate Steering Shaft Replacement - Upper Intermediate Steering Shaft Replacement - Upper ^ Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure 1. Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly. Install the J 42640 in the steering column lower access hole. 2. Important: Mark the relationship of the intermediate shaft components in order to assure proper installation. Mark the relationships of the following components: ^ Mark the relationship of the bolt and clamp at both ends of the upper intermediate shaft. ^ Mark the relationship of the upper intermediate shaft to the lower intermediate shaft. 3. Remove the nut and bolt from the lower shaft to upper shaft connection. 4. Remove the nut and bolt (1) from the upper shaft (2) to steering column connection. 5. Slide the intermediate shaft down, out of the steering column connection. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Intermediate Steering Shaft Replacement - Upper > Page 11062 6. Remove the accelerator pedal position sensor. 7. Slide the upper intermediate shaft towards the instrument panel, out of the lower intermediate shaft, and remove the shaft from the vehicle. Installation Procedure 1. Important: If you are installing the same shaft, align the marks and the relationship of the bolt and clamp made during the removal procedure. Install the lower end of the upper intermediate shaft through the bulkhead, into the lower shaft. 2. Install the upper end of the upper intermediate shaft (2) to the steering column. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the bolt and nut (1) at the connection of the upper intermediate shaft to the steering column. ^ Tighten the nut to 62 Nm (46 ft. lbs.). 4. Install the accelerator pedal position sensor. 5. Install the bolt and nut at the connection of the upper intermediate shaft to the lower intermediate shaft. ^ Tighten the nut to 47 Nm (35 ft. lbs.). 6. Remove the J 42640 from the steering column lower access hole. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Intermediate Steering Shaft Replacement - Upper > Page 11063 Steering Shaft: Service and Repair Intermediate Steering Shaft Replacement - Lower Intermediate Steering Shaft Replacement - Lower ^ Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure Caution: Refer to SIR Caution in Service Precautions. Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly. 1. Set the front wheels in the straight-ahead position. 2. Install the J 42640 in the steering column lower access hole. 3. For vehicles equipped with a 6.6L Diesel, remove the left charge air cooler hose. 4. Mark the relationship of the intermediate shaft components in order to assure proper installation. 1. Mark the relationship of the upper intermediate shaft to the lower intermediate shaft. 2. Mark the relationship of the lower shaft coupler to the steering gear input shaft. 5. Remove the bolt from the upper to lower shaft connection. 6. Remove the bolt from the lower shaft coupler. 7. Remove the intermediate shaft assembly. Slide the shaft towards the dash in order to get the lower shaft coupler clear of the steering gear input shaft. 8. Slide the intermediate shaft down out of the upper shaft. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Intermediate Steering Shaft Replacement - Upper > Page 11064 1. Install the upper end of the intermediate shaft into the upper shaft. 2. Install the lower end of the intermediate shaft coupler. 1. If you are reinstalling the same shaft, align the marks made during the removal procedure. 2. Install the lower end of the intermediate shaft coupler onto the steering gear worm shaft. 3. Install the bolt to the lower shaft coupler. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the bolt to the upper end of the shaft. ^ Tighten the upper bolt to 47 Nm (35 ft. lbs.). ^ Tighten the coupler pinch bolt to 47 Nm (35 ft. lbs.). 5. For vehicles equipped with a 6.6L Diesel, remove the left charge air cooler hose. 6. Remove the J 42640 from the steering column lower access hole. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair Steering Wheel: Service and Repair Steering Wheel Replacement ^ Tools Required J 1859-A Steering Wheel Puller - J 36541-A Steering Wheel Puller Adapter - J 42578 Steering Wheel Puller Legs Removal Procedure 1. Disable the supplemental inflatable restraint (SIR) system. 2. Remove the inflator module. Refer to Horn Switch Replacement in SIR. 3. Remove the horn switch. Refer to Horn Switch Replacement. 4. Make an alignment mark in order to note the relationship of the steering wheel to the steering shaft. 5. Remove the steering wheel nut. 6. Remove the steering wheel using: ^ J 1859-A (1) with ^ J 36541-A (2) or J 42578 (2) Installation Procedure 1. Align the marks made during the removal of the steering shaft and the steering wheel. 2. Install the steering wheel onto the steering shaft. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the steering wheel nut to the steering shaft. ^ Tighten the nut to 40 Nm (29 ft. lbs.). 4. Install the horn switch. Refer to Horn Switch Replacement. 5. Install the inflator module. 6. Enable the SIR system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner Tie Rod End: Service and Repair Inner Rack and Pinion Inner Tie Rod Replacement ^ Tools Required J 34028 Inner Tie Rod Wrench Removal Procedure 1. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly from the vehicle. 3. Remove the rack and pinion boot. Refer to Rack and Pinion Boot Replacement - On Vehicle. Notice: Do not change the rack bearing preload adjustment before removing the inner tie rod from the steering rack. This could cause damage to the pinion or the steering rack or both. 4. Remove the shock dampener (2) from the inner tie rod (5). 5. Slide the shock dampener (2) back onto the rack (1). Important: Do not hold the steering rack while removing the inner tie rod if the preload adjustment has not been changed. 6. Remove the inner tie rod (5) from the rack assembly (1) as follows: 1. Place a wrench on the flats of the inner tie rod housing (4) 2. Rotate the inner tie rod housing (4) counterclockwise until the inner tie rod (5) separates from the rack. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 11073 7. Remove the old Loctite® from the threads (2) of the rack (1) and the inner tie rod (3). Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 11074 1. Important: Make sure the shock dampener is on the rack before installing the inner tie rod. The threads must be clean prior to the Loctite® application. Check the Loctite®, or equivalent, container for expiration date. Use only enough Loctite® to evenly coat the threads. Apply Loctite® 262, or equivalent, to the inner tie rod threads (2). 2. Install the inner tie rod (3) to the rack and pinion (1). 3. Notice: Refer to Fastener Notice in Service Precautions. Install a torque wrench (5) to the J 34028 to tighten the inner tie rod (6).Hold the rack while tightening the tie rod as shown. ^ Tighten the inner tie rod to 100 Nm (74 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 11075 4. Slide the shock dampener (2) over the inner tie rod housing (3) until the front lip of the shock dampener bottoms out against the inner tie rod housing. 5. Install the rack and pinion boot. Refer to Rack and Pinion Boot Replacement - On Vehicle. 6. Install the tire and wheel assembly to the vehicle. 7. Remove the safety stands. 8. Lower the vehicle. 9. Check the wheel alignment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 11076 Tie Rod End: Service and Repair Outer Rack and Pinion Outer Tie Rod End Replacement ^ Tools Required J 24319-01 Universal Steering Linkage Puller Removal Procedure 1. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the torque prevailing nut from outer tie rod stud. 4. Loosen the jam nut (2) on the inner tie rod assembly (1). 5. Remove the outer tie rod assembly (2) from the steering knuckle (1) using J 24319-01. 6. Remove the outer tie rod assembly (3) from the inner tie rod assembly (1). Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 11077 1. Connect the outer tie rod assembly (3) to the inner tie rod (1). Do not tighten the jam nut (2). 2. Install the tie rod seal (2) to the outer tie rod assembly (1). 3. Connect the outer tie rod assembly (1) to the steering knuckle (2). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the torque prevailing nut (3) to the outer tie rod stud (1). ^ Tighten the torque prevailing nut (3) to 50 Nm (37 ft. lbs.). 5. Important: Be sure the rack and pinion boot is not twisted after the toe adjustment. Check the wheel alignment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications Lower Ball Joint Stud Nut .................................................................................................................... .................................................. 100 Nm (74 ft. lbs.) Lower Ball Joint to Lower Control Arm Nuts .......................................................................................................................................... 70 Nm (52 ft. lbs.) Upper Ball Joint Stud Nut ........................................................................................................ ................................................................ 50 Nm (37 ft. lbs.) Wear Limit ............................................. .............................................................................................................................................. 3.18 mm (0.125 inch) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 11082 Ball Joint: Testing and Inspection Ball Joint Inspection ^ Tools Required J 8001 Dial Indicator 1. Important: ^ The vehicle must rest on a level surface. ^ The vehicle must be stable. Do not rock the vehicle on the floor stands. ^ The upper control arm bumper must not contact the frame. Raise and support the vehicle. 2. Support the lower control arm with a floor stand or jack, as far outboard as possible. 3. Important: If a seal is cut or torn, replace the ball joint. Clean and inspect the ball joint seals for cuts or tears. If the ball joint seals are damaged, replace the ball joint. 4. Check the wheel bearing for looseness. If looseness in the wheel bearing is present, refer to Wheel Bearings Diagnosis. 5. Check the ball joints for horizontal looseness. 1. Position the J 8001 dial indicator against the lowest outboard point on the wheel rim. 2. Rock the wheel in and out while reading the dial indicator. This shows horizontal looseness in both joints. 3. The dial indicator reading should be no more than 2 mm (0.080 inch). If the reading is too high, check the lower ball joints for vertical looseness. 6. Notice: Do not pry between the lower arm and the wheel drive shaft boot or in such a manner that the ball joint seal is contacted. Damage to the wheel drive shaft boot will result (4WD). For 4WD vehicles, place a J 8001 dial indicator (1) against the spindle in order to show vertical movement. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 11083 7. Pry between the lower control arm (2) and the outer bearing race (1) while reading the dial indicator. This shows vertical looseness in the lower ball joints. The lower ball joint may show some looseness. 8. If the dial indicator reading is more than 3.18 mm (0.125 inch), replace the lower ball joint. 9. If the lower ball joint is within specifications, and there is too much horizontal looseness, check the upper ball joint for wear. 0. Disconnect the upper ball joint from the steering knuckle. 1. If you find any looseness or can twist the upper ball joint stud with your fingers, replace the upper control arm. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension Ball Joint: Service and Repair Front Suspension (Coil Spring Suspension) Lower Ball Joint Replacement (Coil Spring Suspension) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the lower control arm. Refer to Lower Control Arm Replacement (RWD) Lower Control Arm Replacement (4WD). 4. Secure the lower control arm in a bench vice or equivalent. 5. Center punch the rivet heads. 6. Drill out the rivets. 7. Remove the lower ball joint. Installation Procedure 1. Install the ball joint to the lower control arm. 2. Install the replacement bolts to the lower control arm. 3. Install the nuts to the bolts. ^ Tighten the nuts to 70 Nm (52 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the lower control arm from the bench vice. 5. Install the lower control arm. Refer to Lower Control Arm Replacement (RWD) Lower Control Arm Replacement (4WD). 6. Install the tire and wheel tire assembly. 7. Remove the safety stands. 8. Lower the vehicle. 9. Verify the wheel alignment. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) in Wheel Alignment. (Torsion Bar Suspension) Lower Ball Joint Replacement (Torsion Bar Suspension) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the lower control arm. Refer to Lower Control Arm Replacement (RWD) Lower Control Arm Replacement (4WD). 4. Place the lower control arm in a bench vice. 5. Using a chisel, remove the securing crimps from the ball joint body, if equipped. 6. Using a press, remove the ball joint from the lower control arm. Installation Procedure 1. Install the new ball joint using a press. Important: Use the outer flange of the ball joint in order to press the ball joint into place. 2. Place the lower control arm in a bench vice. 3. Using a punch, install crimps to the ball joint, if necessary. Use the replaced ball joint as a reference. 4. Install the lower control arm. Refer to Lower Control Arm Replacement (RWD) Lower Control Arm Replacement (4WD). 5. Install the tire and wheel assembly. 6. Remove the safety stands. 7. Lower the vehicle. 8. Verify the wheel alignment. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) in Wheel Alignment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension > Page 11086 Ball Joint: Service and Repair Rear Wheel Steering Upper Ball Joint Replacement Upper Ball Joint Replacement ^ Tools Required J 44664 Upper Ball Joint Nut Remover - J 44663 Upper Ball Joint Remover Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the bolt (8) and nut (2) retaining the bracket to the axle. 4. Remove the bracket (7) from the vehicle. 5. Remove the bolt (4) retaining the brake hose bracket (3) to the axle. 6. Using the J 44664 (2), remove the nut (1) retaining the upper ball joint to the steering knuckle. 7. Remove the upper ball joint (3) retaining bolts (2) and stud (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension > Page 11087 8. Using the J 44663 (2) , remove the upper ball joint stud from the steering knuckle. 9. Remove the upper ball joint (1) from the vehicle. Installation Procedure 1. Install the upper ball joint (1) to the steering knuckle. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the upper ball joint retaining bolts (2) and stud (1). ^ Tighten the bolts to 110 Nm (81 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension > Page 11088 3. Install the nut (1) retaining the upper ball joint to the steering knuckle. Use the J 44664 (2) in order to tighten the joint. ^ Tighten the upper ball joint to the steering knuckle nut to 200 Nm (147 ft. lbs.). 4. Install the bracket (7) to the axle. 5. Install the bolt (8) and nut (2) retaining the bracket to the axle. ^ Tighten the bolt and nut to 25 Nm (18 ft. lbs.). 6. Install the bolt (4) retaining the brake hose bracket (3) to the axle. ^ Tighten the brake hose bracket retaining bolt to 12 Nm (106 inch lbs.). 7. Install the tire and wheel. 8. Lower the vehicle. 9. Perform a four wheel alignment. Lower Ball Joint Replacement Lower Ball Joint Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the bolt (8) and nut (2) retaining the bracket to gain access to the pinch bolt. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension > Page 11089 4. Remove the snap ring (2) from the ball joint stud (1). 5. Remove the bolts (2) retaining the lower ball joint (3) to the steering knuckle. 6. Remove the pinch bolt (1) retaining the lower ball. 7. Remove the lower ball joint (2) from the vehicle. Installation Procedure 1. Install the lower ball joint (2) to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension > Page 11090 2. Notice: Refer to Fastener Notice in Service Precautions. Install the bolts (2) retaining the lower ball joint (3) to the steering knuckle. ^ Tighten the bolts to 110 Nm (81 ft. lbs.). 3. Install the lower ball joint pinch bolt (1). ^ Tighten the bolt to 230 Nm (169 ft. lbs.). 4. Install the snap ring (2) to the lower ball joint. 5. Install the bolt (8) and nut (2) retaining the bracket to the axle. ^ Tighten the retaining bolt and nut to 25 Nm (18 ft. lbs.). 6. Install the tire and wheel. 7. Lower the vehicle. 8. Perform a four wheel alignment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Suspension - Revised Upper Control Arm Replacement Control Arm: Technical Service Bulletins Suspension - Revised Upper Control Arm Replacement Bulletin No.: 06-03-08-002 Date: March 09, 2006 SERVICE MANUAL UPDATE Subject: Revised Upper Control Arm Replacement Models: 2003-2006 Cadillac Escalade Models 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe Models 2003-2006 GMC Sierra, Yukon Models 2003-2006 HUMMER H2 This bulletin is being issued to revise the Upper Control Arm Replacement procedure in the Front Suspension sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Use of special tool J 42188-B eliminates the need to remove the wheel drive shaft on 4WD models. Upper Control Arm Replacement (Escalades, Avalanche, Silverado, Sierra, Suburban, Tahoe, Yukons) Tools Required J 42188-B Ball Joint Separator Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 3. Disconnect the electronic suspension control (ESC) link rod from the sensor, if equipped. Refer to Front Position Sensor Link Assembly - Electronic Suspension in Electronic Suspension Control. 4. Remove the retaining bolt for the brake hose and the wheel speed sensor brackets. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Suspension - Revised Upper Control Arm Replacement > Page 11095 5. Remove the upper ball joint retaining nut. 6. Disconnect the upper control arm from the steering knuckle using the J 42188-B. 7. Remove the upper control arm nuts and the adjustment cams (2) for the 15 Series 2WD, 4WD, and 25/35 Series 2WD. 8. Remove the upper control arm bolts (4) for the 15 Series 2WD, 4WD, and 25/35 Series 2WD. 9. Remove the upper control arm nuts and the adjustment cams (2) for the 25/35 Series 4WD. 10. Remove the upper control arm bolts (4) for the 25/35 Series 4WD. 11. Remove the upper control arm. Installation Procedure 1. Install the upper control arm. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Suspension - Revised Upper Control Arm Replacement > Page 11096 2. Install the upper control arm bolts (4) for the 25/35 Series 4WD. Note: Refer to Fastener Notice in Cautions and Notices. 3. Install the upper control arm nuts and the adjustment cams (2) 25/35 Series 4WD. Tighten Tighten the nuts to 190 N.m (140 lb ft). 4. Install the upper control arm bolts (4) for the 15 Series 2WD, 4WD, and 25/35 Series 2WD. 5. Install the upper control arm nuts and the adjustment cams (2) for the 15 Series 2WD, 4WD, and 25/35 Series 2WD. Tighten Tighten the nuts to 190 N.m (140 lb ft). 6. Connect the upper control arm to the steering knuckle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Suspension - Revised Upper Control Arm Replacement > Page 11097 7. Install the new nut to the upper ball joint stud. Tighten Tighten the nut to 50 N.m (37 lb ft). 8. Install the retaining bolts for the brake hose and wheel speed sensor brackets. Tighten Tighten the bolts to 9 N.m (80 lb in). 9. Connect the ESC link rod to the sensor, if equipped. Refer to Front Position Sensor Link Assembly Replacement - Electronic Suspension in Electronic Suspension Control. 10. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 11. Remove the safety stands. 12. Lower the vehicle. 13. Verify the wheel alignment. Refer to Measuring Wheel Alignment in Wheel Alignment. Upper Control Arm Replacement (H2) Tools Required J 42188-B Ball Joint Separator Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Suspension - Revised Upper Control Arm Replacement > Page 11098 3. Remove the retaining bolt for the brake hose and the wheel speed sensor brackets. 4. Remove the nut at the upper ball joint. Discard the nut. 5. Disconnect the upper control arm from the steering knuckle using the J 42188-B. 6. Remove the upper control arm nuts and the adjustment cams. 7. Remove the upper control arm. Installation Procedure 1. Install the upper control arm. Note: Refer to Fastener Notice in Cautions and Notices. 2. Install the upper control arm bolts. Tighten Tighten the nuts to 190 N.m (140 lb ft). 3. Connect the upper control arm to the steering knuckle. 4. Install the new nut to the upper ball joint stud. Tighten Tighten the nut to 50 N.m (39 lb ft). 5. Install the retaining bolts for the brake hose and wheel speed sensor brackets. Tighten Tighten the bolts to 9 N.m (80 lb in). 6. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 7. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Suspension - Revised Upper Control Arm Replacement > Page 11099 8. Verify the wheel alignment. Refer to Wheel Alignment Specifications in Wheel Alignment. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Page 11100 Control Arm: Specifications Lower Control Arm to Frame Nuts ...................................................................................................................................................... 175 Nm (129 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement Control Arm: Service and Repair Upper Control Arm Replacement Upper Control Arm Replacement Tools Required - J-42188-B Ball Joint Separator Removal Procedure 1. Raise and support the vehicle. 2. Remove the tire and wheel. 3. Remove the retaining bolt for the brake hose and the wheel speed sensor brackets. 4. Remove the nut at the upper ball joint. Discard the nut. 5. Disconnect the upper control arm from the steering knuckle using the J-42188-B. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement > Page 11103 6. For 15-Series 2WD/4WD and 25/35 Series 2WD, remove the control arm using the following procedure: 6.1. Remove the upper control arm nuts and the adjustment cams (2). 6.2. Remove the upper control arm bolts (4). 6.3. Remove the upper control arm. 7. For the 25/35 Series 4WD, remove the control arm using the following procedure: 7.1. Remove the upper control arm nuts and adjuster cams (2). 7.2. Remove the upper control arm bolts (4). 7.3. Remove the upper control arm. Installation Procedure 1. Install the upper control arm. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement > Page 11104 2. Install the upper control arm bolts (4), the 25/35 Series for the 4WD. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 3. Install the upper control arm nuts and the adjustment cams (2), the 25/35 Series for the 4WD. - Tighten the nuts to 190 Nm (140 lb ft). 4. For the 25/35 Series 4WD, install the control arm using the following procedure: 4.1. Install the upper control arm. 4.2. Install the upper control arm bolts (4). 4.3. Install the upper control arm nuts and adjuster cams (2). 5. For 15 Series 2WD/4WD and 25/35 Series 2WD, install the control arm using the following procedure: 5.1. Install the upper control arm. 5.2. Install the upper control arm bolts (4). 5.3. Install the upper control arm nuts and the adjustment cams (2). 6. Connect the upper control arm to the steering knuckle. 7. Install a new nut to the upper ball joint stud. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement > Page 11105 - Tighten the nut to 50 Nm (37 lb ft). 8. Install the retaining bolts for the brake hose and wheel speed sensor brackets. - Tighten the bolts to 9 Nm (80 lb in). 9. Install the tire and wheel. 10. Remove the safety stands. 11. Lower the vehicle. 12. Verify the wheel alignment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement > Page 11106 Control Arm: Service and Repair Lower Control Arm Replacement Lower Control Arm Replacement (4WD) ^ Tools Required ^ J 43631 Ball Joint Remover ^ J 45851 Ball Joint Separator Protector Adapters Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the stabilizer shaft links from the lower control arm. Refer to Stabilizer Shaft Replacement. 4. Remove the shock absorber lower nut and the bolt. Refer to Shock Absorber Replacement (4WD) Shock Absorber Replacement (RWD). 5. Remove the torsion bars. Refer to Torsion Bar Replacement. 6. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts. 7. Remove the lower ball joint retaining nut. 8. Disconnect the lower ball joint stud from the steering knuckle using J 43631 and J 45851. 9. Remove the lower control arm nuts and the 15-series washers. 10. Remove the lower control arm bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement > Page 11107 11. Remove the lower control arm nuts and the 25/35-series washers. 12. Remove the lower control arm bolts. 13. Remove the lower control arm. Installation Procedure 1. Install the lower control arm. 2. Install the lower control arm 15-series bolts. 3. Install the lower control arm 25/35-series bolts. 4. Install the washers with the shoulder facing the arm. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement > Page 11108 5. Install the lower control arm retaining nuts. ^ Tighten the nuts to 175 Nm (129 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts. 7. Connect lower ball joint stud to the steering knuckle. 8. Install the retaining nut to the lower ball joint stud. ^ Tighten the nut to 100 Nm (74 ft. lbs.). 9. Install the torsion bars. Refer to Torsion Bar Replacement. 10. Install the shock absorber lower nut and bolt. Refer to Shock Absorber Replacement (4WD) Shock Absorber Replacement (RWD). 11. Install the stabilizer shaft links to the lower control arm. Refer to Stabilizer Shaft Replacement. 12. Install the tire and wheel. 13. Remove the safety stands. 14. Lower the vehicle. 15. Align the vehicle. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) in Wheel Alignment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Body/Frame - Revised Crossmember/Body Bolt Service Cross-Member: Technical Service Bulletins Body/Frame - Revised Crossmember/Body Bolt Service Bulletin No.: 05-08-61-005 Date: April 29, 2005 SERVICE MANUAL UPDATE Subject: Revised Crossmember/Body Mount Bolt Installation Information Models: 1999-2005 Cadillac Full-Size Pickup and Utility Models 1999-2005 Chevrolet Full-Size Pickup and Utility Models 1999-2005 GMC Full-Size Pickup and Utility Models This bulletin is being issued to revise all repair procedures that include reinstalling the front engine crossmember-to-frame bolts or any body mount bolts in the Frame and Underbody sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Before reinstalling front engine crossmember-to-frame bolts or any body mount bolts, you must do the following: 1. Remove all traces of the original thread locking material. 2. Clean the threads of the bolt with denatured alcohol, or equivalent, and allow to dry. 3. Apply Thread locker, P/N 12345493, (Canadian P/N 10953488). Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember Replacement - Front Engine (4WD) Cross-Member: Service and Repair Crossmember Replacement - Front Engine (4WD) Crossmember Replacement - Front Engine (4WD) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the differential carrier shield. 3. Remove the bolts retaining the crossmember to the frame. 4. Remove the crossmember from the vehicle. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember Replacement - Front Engine (4WD) > Page 11115 1. Install the crossmember to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts retaining the crossmember to the frame. Tighten the crossmember retaining bolts to 120 N.m (88 lb ft). 3. Install the differential carrier shield. 4. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember Replacement - Front Engine (4WD) > Page 11116 Cross-Member: Service and Repair Transmission Support Replacement Transmission Support Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Remove the nut retaining the transmission mount to the transmission support. 4. Raise the rear of the transmission. 5. Remove the bolts and the nuts retaining the transmission support to the frame. (15 series) 6. Remove the bolts and the nuts retaining the transmission support to the frame. (25/35 series) 7. Remove the transmission support from the frame. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember Replacement - Front Engine (4WD) > Page 11117 1. Install the transmission support to the frame. (15 series) 2. Install the transmission support to the frame. (25/35 series) Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolts and the nuts in order to retain the transmission support to the frame. Tighten the nuts to 95 N.m (70 lb ft). 4. Lower the rear of the transmission. 5. Install the transmission mount to the transmission support. 6. Install the nuts in order to retain the transmission mount to the transmission support. Tighten the nuts to 40 N.m (30 lb ft). 7. Remove the transmission jack. 8. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Rear Front Steering Knuckle: Service and Repair Rear Steering Knuckle Replacement ^ Tools required J 24319-B Universal Steering Linkage Puller Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the wheel hub and bearing. 4. Remove the upper ball joint. 5. Remove the lower ball joint. 6. Remove the outer tie rod retaining nut and bracket (2). 7. Disconnect the outer tie rod from the steering knuckle using the J 24319-B (1). 8. Remove the park brake cable retaining bolt (3) from the steering knuckle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Rear > Page 11122 9. Remove the steering knuckle (2) from the vehicle. Installation Procedure 1. Install the steering knuckle (2) to the vehicle. 2. Install the upper ball joint. 3. Install the lower ball joint. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake cable retaining bolt (3) to the steering knuckle. ^ Tighten the bolt to 65 Nm (48 ft. lbs.). 5. Install the wheel hub and bearing. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Rear > Page 11123 6. Install the outer tie rod retaining nut to the steering knuckle. ^ Tighten the nut to 55 Nm (40 ft. lbs.). 7. Install the outer tie rod retaining bracket (2). ^ Tighten the bracket to 65 Nm (48 ft. lbs.). 8. Install the tire and wheel. 9. Lower the vehicle. 10. Perform a four wheel alignment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Rear > Page 11124 Front Steering Knuckle: Service and Repair Front Steering Knuckle Replacement (4WD) ^ Tools Required ^ J 43631 Ball Joint Remover ^ J 45851 Ball Joint Separator Protector Adapters Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the wheel hub and bearing assembly. Refer to Wheel Hub, Bearing, and Seal Replacement (RWD) Wheel Hub, Bearing, and Seal Replacement (4WD). 4. Support the lower control arm with a suitable jack. 5. Disconnect the outer tie rod to the steering knuckle. Refer to Tie Rod Replacement in Steering Linkage (Non- Rack and Pinion). 6. Remove the brake hose bracket retaining bolt from the steering knuckle. 7. Remove the upper control arm retaining nut and separate the upper ball joint from the steering knuckle using the J 43631 and J 45851. 8. Remove the lower control arm retaining nut. Separate the lower ball joint from the steering knuckle using the J 43631 and J 45851. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Rear > Page 11125 9. Remove the steering knuckle. Installation Procedure 1. Clean all grease and contaminants from the tapered section and the threads of the upper ball joint, the lower ball joint, and the tie rod end. 2. Clean and inspect the taper holes and the mounting surfaces of the steering knuckle. If any of the tapered holes are elongated, out of round, or damaged, replace the steering knuckle. 3. Install the steering knuckle. 4. Notice: Refer to Fastener Notice in Service Precautions. Connect the lower ball joint to the steering knuckle and install the retaining nut. ^ Tighten the lower control arm retaining nut to 100 Nm (74 ft. lbs.). 5. Connect the upper ball joint to the steering knuckle and install the retaining nut. ^ Tighten the upper control arm retaining nut to 50 Nm (37 ft. lbs.). 6. Install the brake hose and the bracket retaining bolt to the steering knuckle ^ Tighten the bolt to 9 Nm (80 inch lbs.). 7. Connect the outer tie rod to the steering knuckle. Refer to Tie Rod Replacement in Steering Linkage (Non-Rack and Pinion). 8. Install the wheel hub and bearing assembly. Refer to Wheel Hub, Bearing, and Seal Replacement (RWD) Wheel Hub, Bearing, and Seal Replacement (4WD). 9. Install the tire and wheel. 10. Remove the lower control arm support. 11. Lower the vehicle. 12. Align the vehicle. Refer to Measuring Wheel Alignment (w/Rear Wheel Steering) Measuring Wheel Alignment (w/o Rear Wheel Steering) in Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Rear > Page 11126 Wheel Alignment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Rear Position Sensor Replacement Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the steering gear protection shield (1) retaining bolts (3). 3. Disconnect the electrical connector (1). 4. Notice: When removing the rear position cover from the steering gear be careful not to damage to the rear position sensor. Remove the rear wheel position sensor cover (4) from the steering gear by prying on the cover using the slot. 5. Remove the rear wheel position sensor retaining bolts (3). 6. Important: Check the inner tie rod boot for wear or damage. If the boots are damaged replace the steering gear actuator. 7. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Page 11131 Maintain the sensor position. Do not turn the sensor. Remove the rear wheel position sensor (2) from the steering gear. Installation Procedure 1. Important: Make sure the O-ring (1) is installed. Install the rear wheel position sensor (2) to the steering gear. 2. Important: Be careful to maintain the position of the replacement sensor. Remove the pin retaining the position of the new sensor and immediately install the sensor to the steering gear. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the rear wheel position sensor retaining bolts. Apply LOCTITE 242 blue. ^ Tighten the bolts to 4 Nm (35 inch lbs.). 4. Install the rear wheel position sensor cover (4). 5. Connect the electrical connector (1). 6. Install the steering gear protection shield (1) and retaining bolts (3). ^ Tighten the steering gear protection shield retaining bolts to 180 Nm (132 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Page 11132 7. Lower the vehicle. 8. Perform a four wheel alignment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair Suspension Mode Switch: Service and Repair Electronic Suspension Ride Control Switch Replacement Removal Procedure 1. Remove the instrument panel trim bezel. 2. Remove the switch from the lower opening of the switch plate panel. 3. Disconnect the electrical connector. Installation Procedure 1. Connect the electrical connector. 2. Install the switch into the lower opening of the switch plate panel. 3. Install the instrument panel trim bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair > Front Suspension Stabilizer Bushing: Service and Repair Front Suspension Stabilizer Shaft Insulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the oil pan skid plate, if equipped. 4. Remove the stabilizer shaft insulator bracket bolts (3). 5. Remove the stabilizer shaft bracket (2). 6. Lower the stabilizer bar to remove the stabilizer shaft insulators (1). 7. Inspect all of the parts for wear and damage. Installation Procedure 1. Install the stabilizer shaft insulators (1) to the stabilizer shaft (4). Important: Place the insulators on the stabilizer shaft with the slits facing toward the front of the vehicle. 2. Install the stabilizer shaft (4) brackets (2) over the insulators. 3. Install stabilizer shaft insulator bracket bolts (3). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair > Front Suspension > Page 11141 1. Tighten the bolts to 33 Nm (24 ft. lbs.), 15 series. 2. Tighten the bolts to 50 Nm (39 ft. lbs.), 25/35 series. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the stabilizer links. Refer to Stabilizer Shaft Link Replacement. 5. Install the oil pan skid plate, if equipped. ^ Tighten the oil pan skid plate retaining bolts to 20 Nm (15 ft. lbs.). 6. Install the tire and wheel assembly. 7. Remove the safety stands. 8. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair > Front Suspension > Page 11142 Stabilizer Bushing: Service and Repair Rear Suspension Stabilizer Shaft Insulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the stabilizer shaft insulator bracket mounting bolts, 15/25 series shown, 35 series similar. 3. Remove the stabilizer shaft insulators brackets. 4. Lower the stabilizer shaft and remove the stabilizer shaft insulators. 5. Inspect all of the parts for wear or damage. Installation Procedure 1. Important: Place the stabilizer shaft insulators on the stabilizer bar with the slits facing toward the front of the vehicle. Install the stabilizer shaft insulators to the stabilizer bar. 2. Install the stabilizer shaft insulator brackets to the rear axle, 15/25 series shown, 35 series similar. 3. Notice: Refer to Fastener Notice in Service Precautions. Install the stabilizer shaft bracket mounting bolts. ^ Tighten the insulator bracket bolts to 33 Nm (24 ft. lbs.). 4. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Suspension - Revised Stabilizer Link Service/Torque Stabilizer Link: Technical Service Bulletins Suspension - Revised Stabilizer Link Service/Torque Bulletin No.: 05-03-08-006 Date: April 12, 2005 SERVICE MANUAL UPDATE Subject: Revised Stabilizer Shaft Link Replacement Procedure and Fastener Tightening Specifications Models: 1999-2005 Chevrolet and GMC Full Size Pickup and Utility Models 2003-2005 HUMMER H2 This bulletin is being issued to revise the Stabilizer Shaft Link Replacement Procedure and Fastener Tightening Specifications in the Front Suspension sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The following revision affects both the Fastener Tightening Specifications and the Stabilizer Shaft Link Replacement procedure. Pickup and Utility Models : Stabilizer Shaft Link Nuts - 10 Nm (89 lb in) Continue tightening the nut until 2 to 4 threads protrude above the nut. H2 : Stabilizer Shaft Link Nuts - 14 Nm (124 lb in) Continue tightening the nut until 2 to 4 threads protrude above the nut. The following Notice has been added to the Stabilizer Shaft Link Replacement procedure. Note: To avoid stabilizer shaft damage due to loss of clamp load, the threads of the link bolt must protrude 2 to 4 threads above the nut after the specified torque is achieved. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension Stabilizer Link: Service and Repair Front Suspension The content of this article reflects the changes identified in TSB 05-03-08-006. Stabilizer Shaft Link Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the stabilizer shaft nut (1) from the link bolt. 3. Remove the stabilizer shaft link bolt (3). 4. Remove the stabilizer shaft link insulators and spacers (2). 5. Inspect all of the parts for wear and damage. Installation Procedure 1. Install the stabilizer shaft link insulators and spacers (2). 2. Perform the following procedure before installing the stabilizer link bolts. ^ Remove all traces of the original adhesive patch. ^ Apply Threadlocker GM P/N 12345382 (Canadian P/N 10953489) BLUE LOCTITE # 242 on the threads of the bolts. 3. Install the stabilizer shaft link bolts (3). 4. Notice: Refer to Fastener Notice in Service Precautions. Install the stabilizer shaft nut (1) to the link bolt. ^ Tighten the nut to 10 Nm (89 inch lbs.). Continue tightening the nut until 2-4 threads protrude above the nut. 5. Remove the safety stands. 6. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 11149 Stabilizer Link: Service and Repair Rear Suspension Stabilizer Shaft Link Replacement (15/25 Series) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the stabilizer shaft link nut and bolt from the frame bracket. 3. Remove the stabilizer shaft link nut from the ball stud. 4. Remove the stabilizer shaft link. Installation Procedure 1. Install the stabilizer shaft link. 2. Install the stabilizer shaft link nut to the ball stud. Important: When tightening the lower link nut verify that the inner jam nut bottoms out on the ball stud. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 11150 3. Install the stabilizer shaft link nut and bolt to the frame bracket. Notice: Refer to Fastener Notice in Service Precautions. 1. Tighten the link to frame bracket nut to 65 Nm (48 ft. lbs.). 2. Tighten the ball stud to stabilizer shaft nut to 65 Nm (48 ft. lbs.). 4. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Damping Control Actuator > Component Information > Locations Chassis And License Lamp Harnesses Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Service and Repair Suspension Mode Switch: Service and Repair Electronic Suspension Ride Control Switch Replacement Removal Procedure 1. Remove the instrument panel trim bezel. 2. Remove the switch from the lower opening of the switch plate panel. 3. Disconnect the electrical connector. Installation Procedure 1. Connect the electrical connector. 2. Install the switch into the lower opening of the switch plate panel. 3. Install the instrument panel trim bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Leaf Spring Bushing > Component Information > Service and Repair Leaf Spring Bushing: Service and Repair Spring Bushing Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the leaf spring assembly from vehicle. Refer to Leaf Spring Replacement. 3. Remove the bushing from the leaf spring using the following procedure: 1. Place the leaf spring in a press. 2. Press the bushing out. 3. Clean the spring bushing bore of any foreign or old bushing material. Installation Procedure 1. Apply rubber lubricant to the bushing (1) and spring eye (2). 2. Install the bushing to the leaf spring. 1. Place the leaf spring in a press. 2. Press the bushing into the spring. 3. Install the leaf spring assembly to the vehicle. Refer to Leaf Spring Replacement. 4. Remove the safety stands. 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Shackle > Component Information > Service and Repair Shackle: Service and Repair Spring Shackle Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the leaf spring assembly from vehicle. Refer to Leaf Spring Replacement. 3. Remove the shackle nut and the bolt from the spring. Installation Procedure 1. Install the shackle to the spring. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the shackle nut and bolt to the spring. ^ Tighten the shackle nut to 95 Nm (70 ft. lbs.). 3. Install the leaf spring assembly to the vehicle. Refer to Leaf Spring Replacement. 4. Remove the safety stands. 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 03-03-08-002B > Nov > 05 > Suspension Rattles/Squeaks From Front of Vehicle Suspension Strut / Shock Absorber: Customer Interest Suspension - Rattles/Squeaks From Front of Vehicle Bulletin No.: 03-03-08-002B Date: November 30, 2005 TECHNICAL Subject: Rattle/Squeak from Front of Vehicle (Replace Lower Portion of Upper Insulator Assembly) Models: 2002-2005 Cadillac Escalade, Escalade EXT 2003-2005 Cadillac Escalade ESV 2000-2005 Chevrolet Silverado, Suburban, Tahoe 2002-2005 Chevrolet Avalanche 2000-2005 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to update the correction and parts information. Please discard Corporate Bulletin Number 03-03-08-002A (Section 03 - Suspension). Condition Some customers may comment on a rattle or squeak type noise coming from the front of the vehicle. Cause The front shock absorber plastic pilot ring may be wearing out, causing the shock to misalign in the insulator. Correction DO NOT replace the shock. Replace the lower portion, P/N 15834275 , of the upper insulator assembly using the procedure listed below. This new insulator has a taller plastic pilot ring that is attached to the metal sleeve to aid in the proper alignment of the insulators. 1. Remove the front shock absorber. Refer to the Shock Absorber Replacement procedure in the Front Suspension sub-section of the Service Manual. 2. Remove the lower portion of the upper insulator from the shock and discard. 3. Install the new lower portion of the upper insulator to the shock. Important: Be sure to center the shock in the frame bracket and tighten the upper mounting nut when the vehicle is on the ground. 4. Install the front shock absorber. Refer to the Shock Absorber Replacement procedure in the Front Suspension sub-section of the Service Manual. Parts Information Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 03-03-08-002B > Nov > 05 > Suspension Rattles/Squeaks From Front of Vehicle > Page 11173 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 05-03-08-002C > Oct > 09 > Suspension - Shock Absorber/Strut Leakage Information Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Shock Absorber/Strut Leakage Information INFORMATION Bulletin No.: 05-03-08-002C Date: October 16, 2009 Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures. Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension). This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage. Improper diagnosis may lead to components being replaced that are within the manufacturer's specification. Shock absorbers and strut assemblies are fluid-filled components and will normally exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage. Use the following information to determine if the condition is normal acceptable seepage or a defective component. Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to this oil film. Often this film and dust can be wiped off and will not return until similar mileage is accumulated again. Inspection Procedure Note The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Use the following descriptions and graphics to determine the serviceability of the component. Shock Absorbers Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal. Replace shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal. Coil-over Shock Absorber Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 05-03-08-002C > Oct > 09 > Suspension - Shock Absorber/Strut Leakage Information > Page 11179 Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock absorber components and not originating from the shaft seal (located at the top of the coil-over shock tube). 2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal. Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal. Struts Do Not Replace Struts displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and originating from the shaft seal. Replace Struts displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and originating from the shaft seal. Correction Use the information published in SI for diagnosis and repair. Use the applicable published labor operation. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 03-03-08-002B > Nov > 05 > Suspension - Rattles/Squeaks From Front of Vehicle Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Rattles/Squeaks From Front of Vehicle Bulletin No.: 03-03-08-002B Date: November 30, 2005 TECHNICAL Subject: Rattle/Squeak from Front of Vehicle (Replace Lower Portion of Upper Insulator Assembly) Models: 2002-2005 Cadillac Escalade, Escalade EXT 2003-2005 Cadillac Escalade ESV 2000-2005 Chevrolet Silverado, Suburban, Tahoe 2002-2005 Chevrolet Avalanche 2000-2005 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to update the correction and parts information. Please discard Corporate Bulletin Number 03-03-08-002A (Section 03 - Suspension). Condition Some customers may comment on a rattle or squeak type noise coming from the front of the vehicle. Cause The front shock absorber plastic pilot ring may be wearing out, causing the shock to misalign in the insulator. Correction DO NOT replace the shock. Replace the lower portion, P/N 15834275 , of the upper insulator assembly using the procedure listed below. This new insulator has a taller plastic pilot ring that is attached to the metal sleeve to aid in the proper alignment of the insulators. 1. Remove the front shock absorber. Refer to the Shock Absorber Replacement procedure in the Front Suspension sub-section of the Service Manual. 2. Remove the lower portion of the upper insulator from the shock and discard. 3. Install the new lower portion of the upper insulator to the shock. Important: Be sure to center the shock in the frame bracket and tighten the upper mounting nut when the vehicle is on the ground. 4. Install the front shock absorber. Refer to the Shock Absorber Replacement procedure in the Front Suspension sub-section of the Service Manual. Parts Information Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 03-03-08-002B > Nov > 05 > Suspension - Rattles/Squeaks From Front of Vehicle > Page 11184 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 05-03-08-002C > Oct > 09 > Suspension - Shock Absorber/Strut Leakage Information Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Shock Absorber/Strut Leakage Information INFORMATION Bulletin No.: 05-03-08-002C Date: October 16, 2009 Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures. Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension). This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage. Improper diagnosis may lead to components being replaced that are within the manufacturer's specification. Shock absorbers and strut assemblies are fluid-filled components and will normally exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage. Use the following information to determine if the condition is normal acceptable seepage or a defective component. Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to this oil film. Often this film and dust can be wiped off and will not return until similar mileage is accumulated again. Inspection Procedure Note The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Use the following descriptions and graphics to determine the serviceability of the component. Shock Absorbers Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal. Replace shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal. Coil-over Shock Absorber Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 05-03-08-002C > Oct > 09 > Suspension - Shock Absorber/Strut Leakage Information > Page 11190 Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock absorber components and not originating from the shaft seal (located at the top of the coil-over shock tube). 2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal. Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal. Struts Do Not Replace Struts displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and originating from the shaft seal. Replace Struts displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and originating from the shaft seal. Correction Use the information published in SI for diagnosis and repair. Use the applicable published labor operation. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Page 11191 Suspension Strut / Shock Absorber: Specifications Shock Absorber Tension Nut (4WD) ....................................................................................................................................................... 20 Nm (15 ft. lbs.) Shock Absorber to Lower Control Arm Bolts (2WD) .............................................................................................................................. 25 Nm (18 ft. lbs.) Shock Absorber to Lower Control Arm Nut (4WD) ................................................................................................................................ 80 Nm (59 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Suspension Strut / Shock Absorber: Service and Repair Front Suspension Shock Absorber Replacement Shock Absorber Replacement (4WD) Removal Procedure Notice: The front shock absorbers of the vehicle are multifunctional. In addition to contributing to a smooth ride they also provide the only stop to the front suspension when fully extended. Therefore, when servicing the shock absorber, service replacement shock absorbers must be equivalent to original shock absorbers in both extended length and strength. Use of shocks not complying to original equipment or strength could result in suspension over-travel or shock breakage. Suspension over-travel may result in suspension component breakage. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Support the lower control arm with a jack stand. 3. If equipped with selectable ride, disconnect the electrical connector, with the following procedure: 1. Grasp the connector lock tabs (1,2). Rotate the connector tabs counterclockwise until the connector is unlocked. 2. Disengage the connector from the tension by firmly pulling the connector up. 3. Hold the tension end with a wrench while removing the nut. 4. Remove the nut. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 11194 4. Remove the upper insulator (1). Do not discard the plastic pilot ring (2). 5. Remove the shock absorber mounting bolt at the lower control arm, the 15 series. 6. The lower shock mounting bushing is serviceable by driving the bushing out with the appropriate tool. 7. Remove the shock absorber mounting bolt (2) at the lower control arm, the 25 series. 8. Remove the shock absorber. Installation Procedure 1. Install the shock absorber. Insert the stem through the hole in the shock bracket on the frame. 2. Align the shock absorber with the mounting holes in the lower control arm, the 15 series. 3. Align the shock absorber with the mounting holes in the lower control arm, the 25 series. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 11195 4. Install the shock absorber through the bolt (2) to the lower control arm. 5. Install the shock absorber through the bolt nut (3). ^ Tighten the nut to 80 Nm (59 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 6. Install the upper insulator to the shock absorber. Important: The upper insulators are substantially larger that the lower insulators. The upper insulator (1) must be installed above the shock mounting bracket on the frame. The plastic pilot ring (2) will assist the alignment of the isolators. 7. Install the nut to the tension end. Do not tighten the nut. 8. Remove the safety stands. 9. Lower the vehicle. 10. Hold the tension end with a wrench while torquing the nut. ^ Tighten the nut to 20 Nm (15 ft. lbs.). 11. If equipped with selectable ride, connect the electrical connector using the following procedure: 1. Verify that the connector is unlocked. 2. Align the connector so that the tabs (1) are perpendicular to the wrench flats on the tension end. 3. Engage the connector to the tension by firmly pushing the connector down. 4. Grasp the connector lock tabs (1, 2). Rotate the connector counterclockwise. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 11196 12. The connector is locked into place when you hear an audible snap and the tabs (1, 2) are aligned. 13. Dispose of the shock absorber. Refer to Shock Absorber Disposal. Shock Absorber Disposal Shock Absorber Disposal Caution: Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. Caution: To prevent personal injury, wear safety glasses when centerpunching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the centerpunch. 1. Make an indentation 10 mm (0.4 inch) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 inch) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 inch) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 11197 Suspension Strut / Shock Absorber: Service and Repair Rear Shock Absorber Shock Absorber Replacement Shock Absorber Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the electrical connector if equipped with Selectable Ride. 3. Remove the upper shock absorber nut and the bolt. 4. Remove the lower shock absorber nut and the bolt. 5. Remove the shock absorber. Installation Procedure 1. Install the shock absorber. 2. Install the upper shock absorber nut and bolt. 3. Install the lower shock absorber nut and bolt. ^ Tighten the nuts to 95 Nm (70 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Connect the electrical connector if equipped with Selectable Ride. 5. Remove the safety stands. 6. Lower the vehicle. Shock Absorber Disposal Shock Absorber Disposal Caution: Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. Caution: To prevent personal injury, wear safety glasses when centerpunching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the centerpunch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension > Page 11198 1. Make an indentation 10 mm (0.4 inch) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 inch) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 inch) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Front Suspension Suspension Travel Bumper: Service and Repair Front Suspension Spring Bumper Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Unsnap the spring bumper from the mounting cup. For 4WD 15-Series and 2WD 25/35-Series. 3. Remove the nut from the spring bumper stud. For 4WD 15-Series and 2WD 25/35-Series. 4. Remove the spring bumper. Installation Procedure 1. Snap the spring bumper to the mounting cup. For 4WD 15-Series and 2WD 25/35-Series. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Front Suspension > Page 11203 2. Install the spring bumper. For 4WD 15-Series and 2WD 25/35-Series. 3. Install the nut to the spring bumper stud. ^ Tighten the nut to 30 Nm (22 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the safety stands. 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Front Suspension > Page 11204 Suspension Travel Bumper: Service and Repair Rear Suspension Spring Bumper Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the jounce bumper mounting bolt. 3. Remove the jounce bumper. The 15 series utilities are snap fit. Installation Procedure 1. Install the jounce bumper. The 15 series utilities are snap fit. 2. Install the jounce bumper bolt. ^ Tighten the bolt to 32 Nm (24 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. 3. Remove the safety stands. 4. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar Replacement Torsion Bar: Service and Repair Torsion Bar Replacement Torsion Bar Replacement ^ Tools Required J 36202 Torsion Bar Unloading/Loading Tool Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. Notice: Use care when handling the torsion bars in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the torsion bars. 2. Install the J 36202 to the adjustment arm and the crossmember. 3. Increase the tension on the adjustment arm until the load is removed from the adjustment bolt and the adjuster nut. 4. Remove the adjustment bolt (3) and the adjuster nut (4). Important: Mark the adjustment bolt and count the number of times that is required to remove the adjustment bolt. 5. Remove the adjustment bolt (3) and the adjuster nut (4), for vehicles with MN8, MT1 AND MW3. 6. Remove the J 36202 , allowing the torsion bar to unload. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar Replacement > Page 11209 7. Remove the adjustment arm by sliding the torsion bar forward until the torsion bar clears the adjustment arm. Use your hand to support the adjustment arm as the adjustment arm releases from the torsion bar. 8. Remove the torsion bar crossmember bolts (4) from the weld nuts (1). 9. Remove the upper link mounting nuts (1) and the bolts (2). 10. Remove the torsion bar crossmember. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar Replacement > Page 11210 11. Remove the torsion bars from the vehicle. Important: Note the position of the torsion bars as the left and right bars are different. Installation Procedure 1. Install the torsion bars to the lower control arm. 2. Install the torsion bar crossmember. 3. Install the torsion bar crossmember bolts (1) to the weld nuts (4). ^ Tighten the bolt to 95 Nm (70 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar Replacement > Page 11211 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the upper link mounting nuts and the bolts (3). ^ Tighten the nut to 95 Nm (70 ft. lbs.). 5. While supporting the adjustment arm, slide the torsion bar rearward until the torsion bar fully engages the adjustment arm. 6. Install the J 36202 to the adjustment arm and the crossmember. 7. Increase the tension on the adjustment arm in order to load the torsion bar. 8. Install the adjustment bolt (3) and the adjuster nut (4). Important: Install the adjustment bolt the same amount of turns that were required to remove the bolt during removal. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar Replacement > Page 11212 9. Install the adjustment bolt (3) and the adjuster nut (4), for vehicles with MN8, MT1 AND MW3. 10. Remove the J 36202 releasing the tension on the torsion bar until the load is taken up by the adjustment bolt. 11. Remove the safety stands. 12. Lower the vehicle. 13. Measure the Z height. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis. 14. Turn the adjustment bolt (2) clockwise to increase the Z height and counterclockwise to decrease the Z height. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar Replacement > Page 11213 Torsion Bar: Service and Repair Torsion Bars Bushing Replacement Torsion Bars Bushing Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. Important: This procedure requires the removal of both torsion bars. 2. Remove the torsion bars. Refer to Torsion Bar Replacement. 3. Remove the bushing from the bracket utilizing a bushing driver or the equivalent. Installation Procedure 1. Install the bushing to the bracket utilizing a bushing driver or the equivalent. 2. Install the torsion bars. Refer to Torsion Bar Replacement. 3. Remove the safety stands. 4. Lower the vehicle. 5. Measure the Z height. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis. 6. Turn the adjustment bolt clockwise to increase the Z height and counterclockwise to lower the Z height. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Front Hub and Bearing Assembly to Steering Knuckle Bolts ............................................................................................................... 180 Nm (133 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 11217 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Test 1-7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 11218 Wheel Bearing: Adjustments Rear Wheel Bearing Adjustment (With Full Floating 10.5" or 11.5" Ring Gear) IMPORTANT: Ensure the brakes are fully released and do not drag. ^ Pull or push the tire at the top back and forth in order to test the wheel bearing play. ^ Use a pry bar under the tire as an alternative. ^ If the wheel bearing adjustment is correct, the movement will be barely noticeable. ^ If the movement is excessive, adjust the bearings. Adjustment Procedure Tools Required J 2222-C Wheel Bearing Nut Wrench 1. Raise the vehicle. 2. Remove the axle shaft. 3. Remove the hub adjuster nut retaining ring. 4. Remove the adjuster nut lock key. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 11219 5. Tighten the wheel bearing adjusting nut using the J 2222-C. ^ Rotate the hub in the opposite direction to the way the adjuster nut is turning. ^ Ensure the inner bearing and the seal seats against the spindle shoulder. TIGHTEN ^ Adjusting nut to 70 Nm (52.0 lb ft). 6. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 7. Turn the adjusting nut clockwise until the nut contacts the bearing cone. Torque on the nut must be zero to finger tight. 8. Insert the adjusting nut lock key into the keyway using one of the following procedures: ^ If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. IMPORTANT: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. ^ If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 11220 9. Install the retaining ring. 10. Install the axle shaft. 11. Inspect the lubricant level and add, if necessary. 12. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing Wheel Bearing: Service and Repair Front Wheel Bearing Front Wheel Hub, Bearing, and Seal Replacement (4WD) ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 5. Remove the wheel drive shaft nut retaining cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 11223 6. Important: Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 11224 8. Remove the wheel hub and the 15-series bearing mounting bolts (4). 9. Remove the wheel hub and bearing (4) mounting bolts, 25/35 series. 10. Remove the wheel hub and bearing and splash shield from the vehicle. 11. Remove the O-ring seal from the steering knuckle bore, 25/35 series. 12. Remove the wheel speed sensor mounting bolt (5). 13. Clean and inspect the O-ring seal, 25/35 series. 14. Replace the seal if the following conditions exist: ^ Nicks ^ Cuts ^ Dry or brittle ^ Compression set Installation Procedure 1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 3. Install the O-ring (7) to the steering knuckle, the 25/35 series. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. ^ Tighten the sensor mounting bolt to 18 Nm (13 ft. lbs.). 5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 11225 6. Install the wheel hub and bearing (5) and splash shield (6) to the vehicle, 15 series. 7. Install the wheel hub and bearing mounting bolts, the 15 series. 8. Install the wheel hub and bearing mounting bolts, 25/35 series. ^ Tighten the wheel hub to knuckle bolts to 180 Nm (133 ft. lbs.). 9. Install the nut (2) and washer (3) retaining the wheel drive shaft assembly to the wheel hub and bearing. ^ Tighten the nut to 240 Nm (177 ft. lbs.). 10. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. ^ Tighten the brake hose clip bolt to 12 Nm (106 inch lbs.). 11. Install the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 12. Install the tire and wheel. 13. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 11226 Wheel Bearing: Service and Repair With Full Floating 10.5" or 11.5" Ring Gear Rear Axle Hub, Bearing, Cup, and/or Seal Replacement ^ Tools Required J 8092 Universal Driver Handle - 3/4 inch - 10 - J 2222-C Wheel Bearing Nut Wrench - J 24426 Wheel Bearing Race Installer - Outer - J 24427 Wheel Bearing Race Installer - Inner - J 44419 Hub Outer Bearing Race Installer - J 44420 Differential Bearing and Hub Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper. 4. Remove the axle shaft. 5. Remove the axle nut retaining ring. 6. Remove the key. 7. Remove the adjusting nut using the J 2222-C. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 11227 8. Remove the adjusting nut. 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary. 11. Remove the oil seal from the wheel hub using a suitable seal removal tool. 12. Remove the inner hub bearing. 13. Remove the inner hub bearing cup using a brass drift and a hammer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 11228 14. Remove the retaining ring from the wheel hub. 15. Remove the outer hub bearing and bearing cup using the J 24426 (2) and the J 8092 (1). Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: ^ The outer wheel bearing ^ The inner wheel bearing ^ The outer wheel bearing cup ^ The inner wheel bearing cup ^ The axle housing 2. Install the outer bearing into the wheel hub. 3. Install the outer bearing cup into the wheel hub. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 11229 4. Drive the bearing cup into the wheel hub using the J 44419 (2) and the J 8092 (1). 5. Install the retaining ring into the groove. Make sure the retaining ring is fully and evenly seated in the groove. 6. Install the inner bearing cup. 7. Drive the inner bearing cup into the wheel hub using the J 24427 (2) and the J 8092 (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 11230 8. Install the inner bearing. 9. Important: Each time you replace the wheel hub bearings, install a new oil seal in order to prevent the wheel hub from leaking. Install the new oil seal using the J 44420 (2) and the J 8092 (1). 10. Install the rotor, if necessary. 11. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. 12. Install the wheel hub to the axle housing. 13. Install the adjusting nut to the hub using the J 2222-C. 14. Adjust the wheel bearings. 15. Install the axle shaft. 16. Install the brake caliper. 17. Install the tire and wheel assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 11231 18. Inspect and add axle lubricant to the axle housing, if necessary. 19. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 11232 Wheel Bearing: Service and Repair With Rear Wheel Steering Wheel Hub and Bearing Replacement ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. 4. Remove the axle nut dust cover (4). 5. Remove the cotter pin (2) and retainer (3) from the wheel drive shaft nut. 6. Remove the wheel drive shaft retaining nut. 7. Remove the wheel hub and bearing retaining bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 11233 8. Separate the wheel drive shaft from the wheel hub and bearing using J 45859 (2) or equivalent. 9. Remove the wheel hub and bearing (1) from the vehicle. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 11234 1. Install the wheel hub and bearing (3) to the vehicle. 2. Install the wheel hub and bearing retaining bolts. ^ Tighten the bolts to 180 Nm (132 ft. lbs.). 3. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel drive shaft retaining nut. ^ Tighten the nut to 250 Nm (184 ft. lbs.). 4. Install the retainer (3) and cotter pin (2) to the wheel drive shaft nut. 5. Install the dust cap (4). 6. Install the brake rotor. 7. Install the tire and wheel. 8. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Drivetrain - Wheel Drive Shaft Nut Torque Revision Axle Nut: Technical Service Bulletins Drivetrain - Wheel Drive Shaft Nut Torque Revision Bulletin No.: 04-04-95-001 Date: March 02, 2004 SERVICE MANUAL UPDATE Subject: Revised Wheel Drive Shaft Nut Torque Specification Models: 2002-2004 Cadillac Escalade, Escalade EXT 2003-2004 Cadillac Escalade ESV 1999-2004 Chevrolet Silverado 2000-2004 Chevrolet Suburban 2002-2004 Chevrolet Avalanche 2003-2004 Chevrolet Astro, Express 1999-2004 GMC Sierra 2000-2004 GMC Yukon, Yukon XL 2003-2004 GMC Safari, Savana 2003-2004 HUMMER H2 This bulletin is being issued to revise the torque specification for the wheel drive shaft nut in the Wheel Drive Shafts sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Drivetrain - Wheel Drive Shaft Nut Torque Revision > Page 11240 The torque specification for the wheel drive shaft nut has been revised as shown in the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Page 11241 Axle Nut: Specifications Axle Shaft Nut ...................................................................................................................................... ................................................ 240 Nm (177 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes Wheel Hub (Locking): Technical Service Bulletins Drivetrain - Gen II Vs. Gen III Wheel Hub Changes INFORMATION Bulletin No.: 08-03-08-003A Date: March 02, 2009 Subject: Wheel Hub Changes - Gen III vs. Gen II Models: 2008 and Prior Cadillac Escalade Models 2008 and Prior Chevrolet Avalanche, Silverado, Silverado Classic, Suburban, Tahoe 2008 and Prior GMC Sierra, Sierra Classic, Yukon Models Supercede: This bulletin is being revised to update the parts information in the table and to add an Illustrated Hub Gallery depicting all wheel hub part numbers called out below for visual identification purposes. Please discard Corporate Bulletin Number 08-03-08-003 (Section 03 - Suspension). General Motors Vehicle Engineering has introduced a new design Gen III front wheel hub for the above listed vehicles that replaces the Gen II product. These Gen II 4x2 and 4x4 applications that were previously serviced by seven part numbers are now serviced by three Gen III part numbers. Concerns have been expressed by technicians regarding the use of the new supersessions and whether the Gen III hubs will properly fit the vehicles being serviced, especially because of visual and functional differences (splines). This bulletin has been developed to address those concerns. Please refer to the table above for information on the Gen III replacement part for each Gen II application. At the end of the bulletin you will find an illustrated "Hub Gallery" with graphic depictions of both Gen II and replacement style Gen III parts. Using these illustrations you should be able to identify both the Gen II and Gen III wheel hubs. Warning If replacing wheel studs, please refer to the GM Parts Catalog for the correct stud part number for each application. Different types of studs are used depending on the wheel hub application. When replacing an older Gen II design 4x2 hub with a new 4x2/4x4 common Gen III hub, it is acceptable to have a bearing with splines on it for a 4x2 application that previously did not. However, the older Gen II design 4x4 hubs should NOT be used on a 4x2 vehicle. The Gen II 4x4 hub relies on the tension of the wheel drive shaft joint to hold everything together. The roll form feature on the inboard side of the new 4x2/4x4 Gen III hub eliminates this concern. The only hub that is not back serviceable is P/N 15719007 (not pictured) for 1999-2000 C25 applications due to a different hub flange to bearing flange offset. Important: Only the new part numbers referenced in this bulletin are interchangeable between the 4x2 and 4x4 applications with the exception of P/N 15719007 (Not Shown). Under no circumstances should any other 4x4 hub be used in a 4x2 application. Illustrated Hub Gallery Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 11246 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 11247 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 11248 The wheel hubs illustrated above are intended to provide enough visual details to identify subtle differences between the Gen II and Gen III replacement hubs. The various colors used in the graphics are not indicative of any difference or feature, but are used to increase the detail and clarity of the assembly. The associated part number is listed with each illustration. Please refer to the chart above for the specific application for each hub. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 11249 Please note the following when referring to a specific illustration: ^ When using the illustrations for back to back comparisons of two hubs, the most obvious differences are visible on the back side of the hubs. ^ The most common area of physical difference are in the shape of the four mounting bosses and their surrounds. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Seal > Component Information > Service and Repair Wheel Seal: Service and Repair Wheel Hub, Bearing, and Seal Replacement (4WD) ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 5. Remove the wheel drive shaft nut retaining cover. 6. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Seal > Component Information > Service and Repair > Page 11253 Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent. 8. Remove the wheel hub and the 15-series bearing mounting bolts (4). 9. Remove the wheel hub and bearing (4) mounting bolts, 25/35 series. 10. Remove the wheel hub and bearing and splash shield from the vehicle. 11. Remove the O-ring seal from the steering knuckle bore, 25/35 series. 12. Remove the wheel speed sensor mounting bolt (5). 13. Clean and inspect the O-ring seal, 25/35 series. 14. Replace the seal if the following conditions exist: ^ Nicks ^ Cuts Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Seal > Component Information > Service and Repair > Page 11254 ^ Dry or brittle ^ Compression set Installation Procedure 1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 3. Install the O-ring (7) to the steering knuckle, the 25/35 series. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. ^ Tighten the sensor mounting bolt to 18 Nm (13 ft. lbs.). 5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series. 6. Install the wheel hub and bearing (5) and splash shield (6) to the vehicle, 15 series. 7. Install the wheel hub and bearing mounting bolts, the 15 series. 8. Install the wheel hub and bearing mounting bolts, 25/35 series. ^ Tighten the wheel hub to knuckle bolts to 180 Nm (133 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Seal > Component Information > Service and Repair > Page 11255 9. Install the nut (2) and washer (3) retaining the wheel drive shaft assembly to the wheel hub and bearing. ^ Tighten the nut to 240 Nm (177 ft. lbs.). 10. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. ^ Tighten the brake hose clip bolt to 12 Nm (106 inch lbs.). 11. Install the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 12. Install the tire and wheel. 13. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 11271 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Customer Interest for Low Tire Pressure Indicator: > 05-08-49-018A > May > 06 > Instruments - Service Tire Monitor Message is Displayed Low Tire Pressure Indicator: Customer Interest Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Low Tire Pressure Indicator: > 05-08-49-018A > May > 06 > Instruments - Service Tire Monitor Message is Displayed Low Tire Pressure Indicator: All Technical Service Bulletins Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 11298 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Tire/Wheel - Spare Tire Is Non-Matching To Other Tires Spare Tire: Technical Service Bulletins Tire/Wheel - Spare Tire Is Non-Matching To Other Tires INFORMATION Bulletin No.: 02-03-10-001E Date: November 01, 2010 Subject: Spare Tire is a Different Size than Other Tires Models: 2002-2011 Cadillac Escalade Models 1999-2007 Chevrolet Silverado (Classic) 2000-2011 Chevrolet Suburban, Tahoe 2002-2011 Chevrolet Avalanche 1999-2007 GMC Sierra (Classic) 2001 GMC Sierra C3 2001-2011 GMC Yukon Models 2002-2011 GMC Sierra Denali Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-03-10-001D (Section 03 - Suspension). This bulletin is being issued to supply additional information concerning the spare tire on the above vehicles. You or your customers may have noticed that the spare tire has a 16-inch diameter steel wheel or 17-inch diameter aluminum wheel while the road tires have a 17-inch, 18-inch, 20-inch or 22-inch diameter aluminum wheel. Although the spare tire has a different wheel diameter and may be a different brand, the rolling circumference is nearly identical to the road tires. The size difference will not cause a concern because the spare and the other tires will travel the same distance in one revolution. This combination of non-matching tires is used most often on full-size trucks. These vehicles use a road tire and wheel combination that may be too large to conveniently fit the storage compartment space of the vehicle. The customer may not be able to easily remove the spare tire/wheel from the storage area because of its size and/or weight. A steel spare wheel, rather than an aluminum one, may be used since the spare is stowed under the vehicle where it is exposed to road and weather elements. A steel wheel is less likely to incur cosmetic damage while in the stowed position for long periods of time. Please provide this information to your customers. Also, remind your customers of the importance of following the tire maintenance schedule as listed in their Owner Manual. Additional tire care information can be found by visiting www.gmtiresafety.com or contacting GM toll-free. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 11312 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 11313 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 11314 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 11319 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 11324 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 11325 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 11326 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up Wheels: Customer Interest Brakes/Wheels - Excessive Debris Build Up Bulletin No.: 04-05-23-005 Date: June 22, 2004 INFORMATION Subject: Availability of Rear Wheel Mud Flaps to Reduce Debris Build-up on Rear Brake Calipers and/or Rear Wheels Models: 1999-2004 Chevrolet Silverado Pickup Models 1999-2004 GMC Sierra Pickup Models This bulletin is to inform dealers of the release of rear wheel mud flaps. The above models that are exposed to extensive off-paved roads may benefit from the mud flaps. The mud flaps have been developed to minimize the amount of stones and/or mud that can impact and collect on the rear caliper and/or wheel rim. Please advise customers that the installation of these mud flaps and following the recommended off-road driving information provided in their Owner's Manual should greatly reduce the possibility of accelerated rear brake component wear and/or rim damage. Install the mud flap forward of each rear wheel using the following procedure. Important: Always work from outboard to inboard, drilling one hole at a time and securing with a fastener. Follow the sequence of the procedure. This will prevent distortion of the mud flap. 1. Raise the vehicle. Support the vehicle. 2. Locate the pickup box side panel rear brace. 3. Remove the existing outboard upper fastener on the brace. 4. Install the mud flap through the "V" of the brace. Install the previously removed fastener in the hole (2) of the mud flap to the brace. Do not tighten the fastener at this time. 5. Using the mud flap as a template, locate and mark the location of the hole (1) in the pickup box wheel house. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up > Page 11331 Important: After drilling the holes, apply the appropriate anti-corrosion primer. Refer to the GM Refinish Material Booklet # 4901 M-D (English) or # 4901-D-F (French) for additional information. 6. Center punch the marked location and drill a 6.35 mm (1/4 in) hole. Install the plastic retainer in the hole (1) of the mud flap. 7. Tighten fastener at the hole (2) location of the mud flap. Tighten Tighten the fastener to 25 N.m (18 lb ft). 8. For vehicles with short box, use the following procedure: 8.1. Push the mud flap to make contact with the rear side of the underbody cross sill and mark the location of the hole (3) of the mud flap. 8.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 8.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 8.4. Repeat the above steps for hole locations 4 and 6. 9. For vehicles with long box, use the following procedure: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up > Page 11332 9.1. Push the mud flap to make contact with the front side of the underbody cross sill and mark location of the hole (5) of the mud flap. 9.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 9.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 9.4. Repeat the above steps for hole location 6. 10. Repeat the above steps for the opposite side. Parts Information Parts are expected to be available from GMSPO on June 30, 2004. Warranty Information Please advise the customer that the mud flaps can be purchased as an accessory. Installation and/or cost of the mud flaps will not be covered under the vehicle's warranty. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 11338 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 11339 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 11340 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 11345 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 11350 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 11351 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 11356 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 11357 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 11358 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 11363 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 11368 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 11369 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 11370 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up Wheels: All Technical Service Bulletins Brakes/Wheels - Excessive Debris Build Up Bulletin No.: 04-05-23-005 Date: June 22, 2004 INFORMATION Subject: Availability of Rear Wheel Mud Flaps to Reduce Debris Build-up on Rear Brake Calipers and/or Rear Wheels Models: 1999-2004 Chevrolet Silverado Pickup Models 1999-2004 GMC Sierra Pickup Models This bulletin is to inform dealers of the release of rear wheel mud flaps. The above models that are exposed to extensive off-paved roads may benefit from the mud flaps. The mud flaps have been developed to minimize the amount of stones and/or mud that can impact and collect on the rear caliper and/or wheel rim. Please advise customers that the installation of these mud flaps and following the recommended off-road driving information provided in their Owner's Manual should greatly reduce the possibility of accelerated rear brake component wear and/or rim damage. Install the mud flap forward of each rear wheel using the following procedure. Important: Always work from outboard to inboard, drilling one hole at a time and securing with a fastener. Follow the sequence of the procedure. This will prevent distortion of the mud flap. 1. Raise the vehicle. Support the vehicle. 2. Locate the pickup box side panel rear brace. 3. Remove the existing outboard upper fastener on the brace. 4. Install the mud flap through the "V" of the brace. Install the previously removed fastener in the hole (2) of the mud flap to the brace. Do not tighten the fastener at this time. 5. Using the mud flap as a template, locate and mark the location of the hole (1) in the pickup box wheel house. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up > Page 11379 Important: After drilling the holes, apply the appropriate anti-corrosion primer. Refer to the GM Refinish Material Booklet # 4901 M-D (English) or # 4901-D-F (French) for additional information. 6. Center punch the marked location and drill a 6.35 mm (1/4 in) hole. Install the plastic retainer in the hole (1) of the mud flap. 7. Tighten fastener at the hole (2) location of the mud flap. Tighten Tighten the fastener to 25 N.m (18 lb ft). 8. For vehicles with short box, use the following procedure: 8.1. Push the mud flap to make contact with the rear side of the underbody cross sill and mark the location of the hole (3) of the mud flap. 8.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 8.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 8.4. Repeat the above steps for hole locations 4 and 6. 9. For vehicles with long box, use the following procedure: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up > Page 11380 9.1. Push the mud flap to make contact with the front side of the underbody cross sill and mark location of the hole (5) of the mud flap. 9.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 9.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 9.4. Repeat the above steps for hole location 6. 10. Repeat the above steps for the opposite side. Parts Information Parts are expected to be available from GMSPO on June 30, 2004. Warranty Information Please advise the customer that the mud flaps can be purchased as an accessory. Installation and/or cost of the mud flaps will not be covered under the vehicle's warranty. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 07-08-45-002 > Sep > 07 > Electrical - Aftermarket Fuse Warning Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 05-08-49-018A > May > 06 > Instruments - Service Tire Monitor Message is Displayed Fuse: All Technical Service Bulletins Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 04-08-46-005 > Dec > 04 > OnStar(R) - System Inoperative/No LED Lamp ON Fuse: All Technical Service Bulletins OnStar(R) - System Inoperative/No LED Lamp ON Bulletin No.: 04-08-46-005 Date: December 21, 2004 TECHNICAL Subject: OnStar(R) Generation 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models: 2004-2005 Buick Rainier, Rendezvous 2005 Buick Allure (Canada), LaCrosse, LeSabre, Terrazza 2004-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2005 Cadillac CTS, DeVille 2004-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2005 Chevrolet Colorado, Express, Impala, Monte Carlo, Uplander 2004-2005 GMC Denali, Denali XL, Envoy, Envoy XL, Envoy XUV, Sierra, Yukon, Yukon XL 2005 GMC Canyon, Savana 2004-2005 Pontiac Aztek 2005 Pontiac Bonneville, Grand Prix, Montana SV6, Vibe with Digital Gen 6 OnStar(R) (RPO UE1) Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module VCIM) with a Tech 2(R). Correction Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, you will need to replace the VCIM. If the VCIM is not replaced, there is the possibility that the customer will return to the dealership with the same conditions at a later date. Please contact the GM Technical Assistance Center (TAC), to obtain a new VCIM. The TAC consultant will verify your diagnosis and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a significant non-return core charge. After the VCIM has been replaced, press the blue OnStar(R) button and request a full reconfiguration. When contacting TAC regarding this concern, the availability of certain information from the vehicle will streamline the process for the dealership technician as well as minimize the time necessary for TAC to provide the correct diagnosis. Please refer to Corporate Bulletin Number 01-00-89-011B for further information concerning the information necessary before contacting TAC. Dealers in Canada should refer to GM Service Policies & Procedures Section 5.3.1 "DEALER REQUIREMENTS FOR ASSISTANCE". Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 04-08-46-005 > Dec > 04 > OnStar(R) - System Inoperative/No LED Lamp ON > Page 11394 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 04-08-46-005 > Dec > 04 > OnStar(R) - System Inoperative/No LED Lamp ON > Page 11408 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Aluminum Wheel Porosity Repair 1. Remove the tire and wheel. 2. Inflate the tire to the manufactures specified pressure as stated on the tire. 3. Submerge the tire/wheel into a water bath in order to locate the leak. 4. Inscribe a mark on the wheel in order to indicate the leak areas. 5. Inscribe a mark on the tire at the valve stem in order to Indicate the orientation of the tire to the wheel. 6. Remove the tire from the wheel. 7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. Important: Do not damage the exterior surface of the wheel. 8. Use general purpose cleaner such as 3M®, P/N 08984 or equivalent, to clean the leak area. 9. Apply 3 mm (0.12 inch) thick layer of adhesive/sealant, GM P/N 12378478 (Canadian P/N 88900041) or equivalent, to the leak area. 10. Allow for the adhesive/sealant to dry. 11. Align the inscribed mark on the tire with the valve stem on the wheel. 12. Install the tire to the wheel. 13. Inflate the tire to the manufactures specified pressure as stated on the tire. 14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 15. Balance the tire and wheel. 16. Install the tire and wheel. 17. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 11411 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing A protective clear coating covers the surface of original equipment cast aluminum wheels. A surface degradation may develop if frequent automatic car wash cleaning wears off the factory applied protective clear coating. This can happen at some automatic car wash facilities that use aggressive brushes to clean whitewalls and tires. Once you damage the protective clear coating, exposure to caustic cleaners and road salt can cause further surface deterioration. Damage to the protective clear coating is corrected by replacing the damaged wheel. Refinishing is no longer recommended. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 11412 Wheels: Service and Repair Tire and Wheel Removal and Installation Tire and Wheel Removal and Installation ^ Tools Required J 39544-KIT Complete Torque Socket Set Caution: If penetrating oil gets on the vertical surfaces between the wheel and the rotor or drum it could cause the wheel to work loose as the vehicle is driven, resulting in loss of control and an injury accident. Notice: Never use heat to loosen a tight wheel. It can shorten the life of the wheel, studs, or hub and bearing assemblies. Wheel nuts must be tightened in sequence and to the specified torque to avoid bending the wheel or rotor. Notice: Improperly tightened wheel nuts can lead to brake pulsation and rotor damage. In order to avoid expensive brake repairs, evenly tighten the wheel nuts to the proper torque specification. Important: Removing wheels can be difficult because of foreign material or a tight fit between the wheel center hole and the hub or rotor. Excessive force, such as hammering on the wheel or tire, can cause damage. Slightly tapping the tire side wall with a rubber mallet is acceptable. 1. ^ Tighten all wheel nuts on the affected wheel. 2. Loosen each wheel nut 2 turns. 3. Rock the vehicle from side to side in order to loosen the wheel. If this does not loosen the wheel, rock the vehicle front to back applying quick hard jabs to the brake pedal to loosen the wheel. 4. Repeat this procedure if the wheel does not break free. Removal Procedure 1. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to Vehicle Lifting. 2. Remove the wheel center cap. 3. Remove the wheel nuts from the tire and wheel. 4. Mark the location of the tire and wheel to the hub assembly. 5. Remove the tire and wheel from the vehicle. 6. Clean the wheel nuts, studs and the wheel and rotor mounting surfaces. Installation Procedure Caution: Before installing the wheels, remove any buildup of corrosion on the wheel mounting surface and brake drum or disc mounting surface by scraping and wire brushing. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This can cause a wheel to come off when the vehicle is moving, causing loss of control and possibly personal injury. Notice: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel stud, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 11413 1. Install the tire and wheel. Align the locating mark of the tire and wheel to the hub. 2. Install the wheel nuts. ^ Tighten the wheel nuts as shown to 190 Nm (140 ft. lbs.). Notice: Refer to Fastener Notice in Service Precautions. Important: ^ Tighten the nuts evenly and alternately in order to avoid excessive runout. 3. Install the wheel center cap. 4. Remove the safety stands. 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Front Hub and Bearing Assembly to Steering Knuckle Bolts ............................................................................................................... 180 Nm (133 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 11417 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Test 1-7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 11418 Wheel Bearing: Adjustments Rear Wheel Bearing Adjustment (With Full Floating 10.5" or 11.5" Ring Gear) IMPORTANT: Ensure the brakes are fully released and do not drag. ^ Pull or push the tire at the top back and forth in order to test the wheel bearing play. ^ Use a pry bar under the tire as an alternative. ^ If the wheel bearing adjustment is correct, the movement will be barely noticeable. ^ If the movement is excessive, adjust the bearings. Adjustment Procedure Tools Required J 2222-C Wheel Bearing Nut Wrench 1. Raise the vehicle. 2. Remove the axle shaft. 3. Remove the hub adjuster nut retaining ring. 4. Remove the adjuster nut lock key. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 11419 5. Tighten the wheel bearing adjusting nut using the J 2222-C. ^ Rotate the hub in the opposite direction to the way the adjuster nut is turning. ^ Ensure the inner bearing and the seal seats against the spindle shoulder. TIGHTEN ^ Adjusting nut to 70 Nm (52.0 lb ft). 6. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 7. Turn the adjusting nut clockwise until the nut contacts the bearing cone. Torque on the nut must be zero to finger tight. 8. Insert the adjusting nut lock key into the keyway using one of the following procedures: ^ If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. IMPORTANT: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. ^ If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 11420 9. Install the retaining ring. 10. Install the axle shaft. 11. Inspect the lubricant level and add, if necessary. 12. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing Wheel Bearing: Service and Repair Front Wheel Bearing Front Wheel Hub, Bearing, and Seal Replacement (4WD) ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 5. Remove the wheel drive shaft nut retaining cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 11423 6. Important: Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 11424 8. Remove the wheel hub and the 15-series bearing mounting bolts (4). 9. Remove the wheel hub and bearing (4) mounting bolts, 25/35 series. 10. Remove the wheel hub and bearing and splash shield from the vehicle. 11. Remove the O-ring seal from the steering knuckle bore, 25/35 series. 12. Remove the wheel speed sensor mounting bolt (5). 13. Clean and inspect the O-ring seal, 25/35 series. 14. Replace the seal if the following conditions exist: ^ Nicks ^ Cuts ^ Dry or brittle ^ Compression set Installation Procedure 1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 3. Install the O-ring (7) to the steering knuckle, the 25/35 series. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. ^ Tighten the sensor mounting bolt to 18 Nm (13 ft. lbs.). 5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 11425 6. Install the wheel hub and bearing (5) and splash shield (6) to the vehicle, 15 series. 7. Install the wheel hub and bearing mounting bolts, the 15 series. 8. Install the wheel hub and bearing mounting bolts, 25/35 series. ^ Tighten the wheel hub to knuckle bolts to 180 Nm (133 ft. lbs.). 9. Install the nut (2) and washer (3) retaining the wheel drive shaft assembly to the wheel hub and bearing. ^ Tighten the nut to 240 Nm (177 ft. lbs.). 10. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. ^ Tighten the brake hose clip bolt to 12 Nm (106 inch lbs.). 11. Install the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 12. Install the tire and wheel. 13. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 11426 Wheel Bearing: Service and Repair With Full Floating 10.5" or 11.5" Ring Gear Rear Axle Hub, Bearing, Cup, and/or Seal Replacement ^ Tools Required J 8092 Universal Driver Handle - 3/4 inch - 10 - J 2222-C Wheel Bearing Nut Wrench - J 24426 Wheel Bearing Race Installer - Outer - J 24427 Wheel Bearing Race Installer - Inner - J 44419 Hub Outer Bearing Race Installer - J 44420 Differential Bearing and Hub Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper. 4. Remove the axle shaft. 5. Remove the axle nut retaining ring. 6. Remove the key. 7. Remove the adjusting nut using the J 2222-C. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 11427 8. Remove the adjusting nut. 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary. 11. Remove the oil seal from the wheel hub using a suitable seal removal tool. 12. Remove the inner hub bearing. 13. Remove the inner hub bearing cup using a brass drift and a hammer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 11428 14. Remove the retaining ring from the wheel hub. 15. Remove the outer hub bearing and bearing cup using the J 24426 (2) and the J 8092 (1). Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: ^ The outer wheel bearing ^ The inner wheel bearing ^ The outer wheel bearing cup ^ The inner wheel bearing cup ^ The axle housing 2. Install the outer bearing into the wheel hub. 3. Install the outer bearing cup into the wheel hub. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 11429 4. Drive the bearing cup into the wheel hub using the J 44419 (2) and the J 8092 (1). 5. Install the retaining ring into the groove. Make sure the retaining ring is fully and evenly seated in the groove. 6. Install the inner bearing cup. 7. Drive the inner bearing cup into the wheel hub using the J 24427 (2) and the J 8092 (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 11430 8. Install the inner bearing. 9. Important: Each time you replace the wheel hub bearings, install a new oil seal in order to prevent the wheel hub from leaking. Install the new oil seal using the J 44420 (2) and the J 8092 (1). 10. Install the rotor, if necessary. 11. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. 12. Install the wheel hub to the axle housing. 13. Install the adjusting nut to the hub using the J 2222-C. 14. Adjust the wheel bearings. 15. Install the axle shaft. 16. Install the brake caliper. 17. Install the tire and wheel assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 11431 18. Inspect and add axle lubricant to the axle housing, if necessary. 19. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 11432 Wheel Bearing: Service and Repair With Rear Wheel Steering Wheel Hub and Bearing Replacement ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Notice: Refer vehicle Lifting. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. 4. Remove the axle nut dust cover (4). 5. Remove the cotter pin (2) and retainer (3) from the wheel drive shaft nut. 6. Remove the wheel drive shaft retaining nut. 7. Remove the wheel hub and bearing retaining bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 11433 8. Separate the wheel drive shaft from the wheel hub and bearing using J 45859 (2) or equivalent. 9. Remove the wheel hub and bearing (1) from the vehicle. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing > Page 11434 1. Install the wheel hub and bearing (3) to the vehicle. 2. Install the wheel hub and bearing retaining bolts. ^ Tighten the bolts to 180 Nm (132 ft. lbs.). 3. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel drive shaft retaining nut. ^ Tighten the nut to 250 Nm (184 ft. lbs.). 4. Install the retainer (3) and cotter pin (2) to the wheel drive shaft nut. 5. Install the dust cap (4). 6. Install the brake rotor. 7. Install the tire and wheel. 8. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Wheels - Correct Hub Cap Installation Procedure Wheel Cover: Technical Service Bulletins Wheels - Correct Hub Cap Installation Procedure Bulletin No.: 03-03-10-002B Date: November 02, 2005 INFORMATION Subject: Use of Correct Installation Procedure for Loose Hubcap Assembly Models: 1998-2006 Chevrolet Express Van 1999-2006 Chevrolet Silverado Models 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1998-2006 GMC Savana Van 1999-2006 GMC Sierra Models 2000-2006 GMC Yukon, Yukon XL Models Supercede: This bulletin is being revised to add the 2006 model year. Please discard Corporate Bulletin Number 03-03-10-002A (Section 03 - Suspension). Some hubcap assemblies on the above-listed vehicles are being returned to the Warranty Parts Center (WPC) for loose and/or rattle conditions. Some returned hubcaps have the stand-off insulators removed. Analyses of these parts show no out of specification condition. Hubcap assemblies are placed in the vehicle by the assembly plant for dealer installation. Installation is done by threading the six or eight plastic nut caps, which are part of the hubcap assembly, to the external threads of the wheel (lug) nuts. If over-tightened, these plastic nut caps will jump threads, as designed, causing a loose or rattle condition. Important: ^ DO NOT over-tighten the plastic nut caps. ^ DO NOT use an impact wrench on the plastic nut caps. ^ DO NOT modify or remove the stand-off insulators from the plastic hubcap assembly. The nut cap system is designed to skip a thread if over-tightened. DO NOT replace the hubcap assembly if this happens. Hold hubcap (2) firmly in place on wheel with the plastic wheel nut caps (3) aligned with the steel wheel nuts (1). Hand snug each nut cap (3) (using a hand held deep socket or torque stick) until fully seated against the hubcap (2). You should feel the nut cap (3) ratchet against the hubcap (2) a couple times as the nut cap (3) seats. After all nut caps (3) have been seated, check tightness of each nut cap (3) using the socket or torque stick and tighten any nut cap (3) that may have loosened. If a nut cap (3) jumps thread (a design feature to prevent damage) and becomes loose during tightening, continue to tighten and stop short of thread jump. Follow the installation instruction sheet that is included in each hubcap package. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Wheels - Correct Hub Cap Installation Procedure > Page 11439 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Drivetrain - Wheel Drive Shaft Nut Torque Revision Axle Nut: Technical Service Bulletins Drivetrain - Wheel Drive Shaft Nut Torque Revision Bulletin No.: 04-04-95-001 Date: March 02, 2004 SERVICE MANUAL UPDATE Subject: Revised Wheel Drive Shaft Nut Torque Specification Models: 2002-2004 Cadillac Escalade, Escalade EXT 2003-2004 Cadillac Escalade ESV 1999-2004 Chevrolet Silverado 2000-2004 Chevrolet Suburban 2002-2004 Chevrolet Avalanche 2003-2004 Chevrolet Astro, Express 1999-2004 GMC Sierra 2000-2004 GMC Yukon, Yukon XL 2003-2004 GMC Safari, Savana 2003-2004 HUMMER H2 This bulletin is being issued to revise the torque specification for the wheel drive shaft nut in the Wheel Drive Shafts sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Drivetrain - Wheel Drive Shaft Nut Torque Revision > Page 11445 The torque specification for the wheel drive shaft nut has been revised as shown in the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Page 11446 Axle Nut: Specifications Axle Shaft Nut ...................................................................................................................................... ................................................ 240 Nm (177 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes Wheel Hub (Locking): Technical Service Bulletins Drivetrain - Gen II Vs. Gen III Wheel Hub Changes INFORMATION Bulletin No.: 08-03-08-003A Date: March 02, 2009 Subject: Wheel Hub Changes - Gen III vs. Gen II Models: 2008 and Prior Cadillac Escalade Models 2008 and Prior Chevrolet Avalanche, Silverado, Silverado Classic, Suburban, Tahoe 2008 and Prior GMC Sierra, Sierra Classic, Yukon Models Supercede: This bulletin is being revised to update the parts information in the table and to add an Illustrated Hub Gallery depicting all wheel hub part numbers called out below for visual identification purposes. Please discard Corporate Bulletin Number 08-03-08-003 (Section 03 - Suspension). General Motors Vehicle Engineering has introduced a new design Gen III front wheel hub for the above listed vehicles that replaces the Gen II product. These Gen II 4x2 and 4x4 applications that were previously serviced by seven part numbers are now serviced by three Gen III part numbers. Concerns have been expressed by technicians regarding the use of the new supersessions and whether the Gen III hubs will properly fit the vehicles being serviced, especially because of visual and functional differences (splines). This bulletin has been developed to address those concerns. Please refer to the table above for information on the Gen III replacement part for each Gen II application. At the end of the bulletin you will find an illustrated "Hub Gallery" with graphic depictions of both Gen II and replacement style Gen III parts. Using these illustrations you should be able to identify both the Gen II and Gen III wheel hubs. Warning If replacing wheel studs, please refer to the GM Parts Catalog for the correct stud part number for each application. Different types of studs are used depending on the wheel hub application. When replacing an older Gen II design 4x2 hub with a new 4x2/4x4 common Gen III hub, it is acceptable to have a bearing with splines on it for a 4x2 application that previously did not. However, the older Gen II design 4x4 hubs should NOT be used on a 4x2 vehicle. The Gen II 4x4 hub relies on the tension of the wheel drive shaft joint to hold everything together. The roll form feature on the inboard side of the new 4x2/4x4 Gen III hub eliminates this concern. The only hub that is not back serviceable is P/N 15719007 (not pictured) for 1999-2000 C25 applications due to a different hub flange to bearing flange offset. Important: Only the new part numbers referenced in this bulletin are interchangeable between the 4x2 and 4x4 applications with the exception of P/N 15719007 (Not Shown). Under no circumstances should any other 4x4 hub be used in a 4x2 application. Illustrated Hub Gallery Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 11451 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 11452 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 11453 The wheel hubs illustrated above are intended to provide enough visual details to identify subtle differences between the Gen II and Gen III replacement hubs. The various colors used in the graphics are not indicative of any difference or feature, but are used to increase the detail and clarity of the assembly. The associated part number is listed with each illustration. Please refer to the chart above for the specific application for each hub. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Drivetrain - Gen II Vs. Gen III Wheel Hub Changes > Page 11454 Please note the following when referring to a specific illustration: ^ When using the illustrations for back to back comparisons of two hubs, the most obvious differences are visible on the back side of the hubs. ^ The most common area of physical difference are in the shape of the four mounting bosses and their surrounds. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 11463 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 11469 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 11475 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 11476 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 11477 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 11482 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 11483 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 11484 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 11485 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 11486 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 11487 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 09-06-04-034 > Aug > 09 > Fuel System Reduced Engine Power, MIL (Various Codes) Wiring Harness: All Technical Service Bulletins Fuel System - Reduced Engine Power, MIL (Various Codes) TECHNICAL Bulletin No.: 09-06-04-034 Date: August 17, 2009 Subject: Malfunction Indicator Lamp (MIL) Illuminated, Fuel Injector Driver Circuit DTCs P0201, P0202, P0203, P0204, P0205, P0206, P0207, P0208 and Cylinder Bank Shut Down DTCs P2146 or P2149, Reduced Engine Power (Repair Fuel Injector Control Module (FICM) Harness Chafed Wires) Models: 2001-2004 Chevrolet Kodiak C4500/C5500 Series, Silverado Models 2001-2004 GMC Sierra Models, TopKick C4500/C5500 Series Equipped with Duramax(TM) Diesel Engine RPO LB7 2004-2005 Chevrolet Kodiak, Silverado Models 2004-2005 GMC Sierra Models, TopKick Equipped with Duramax Diesel Engine RPO LLY Please Refer to GMVIS Condition Some customers may comment that the malfunction indicator lamp (MIL) is illuminated or intermittent and there is a significant reduction in engine power (limp home mode). The scan tool may display one or more Injector Driver Circuit DTCs P0201, P0202, P0203, P0204, P0205, P0206, P0207 or P0208 and/or Cylinder Bank Shut Down DTCs P2146 or P2149 set as Current or in History. Cause This condition may be caused by the fuel injector control module (FICM) wiring harness protective conduit rubbing against the back of the alternator, the alternator bracket or the FICM harness retaining bracket. This may result in the conduit rubbing through, exposing the wires inside and chafing of the wire insulation then occurs. Correction 1. Turn ON the ignition, with the engine OFF. 2. Observe the DTC information with the scan tool. 3. If any of the above DTCs are set, then proceed to inspect the FICM wiring harness at the locations outlined in the following steps. 4. Turn OFF the ignition and all accessories and allow the control modules to power down. Note For Silverado and Sierra models only perform Step 5. 5. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. Important DO NOT break off the tab on the electrical connectors. 6. Disconnect the FICM electrical connectors (2) from the FICM (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 09-06-04-034 > Aug > 09 > Fuel System Reduced Engine Power, MIL (Various Codes) > Page 11492 7. Carefully bend up and backwards the FICM wiring harness electrical connectors (1) away from the FICM (4). Note Some of these chafes are very small, possibly the size of a pen tip, but could still cause injector circuit concerns. 8. Inspect the wiring harness for chafing (3) that may result from rubbing at the back of the alternator (2), the alternator bracket or at the FICM harness retaining bracket. If necessary, peel the tape from the area and look for ANY chafes into the wires. ^ If chafing is observed and the conductive portion of the wire IS NOT damaged, apply electrical tape around the wire. ^ If chafing is observed and the conductive portion of the wire IS damaged, then refer to Splicing Copper Wire Using Splice Sleeves in Wiring Repairs in SI. ^ If chafing IS NOT OBSERVED, then refer to the appropriate DTC Diagnostic procedures in SI. 9. Connect the electrical connectors to the FICM. 10. Insulate the harness with suitable material such as conduit or heater hose to prevent a reoccurrence. Note For Silverado and Sierra models only perform Step 11. 11. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 12. Clear the DTCs with a scan tool. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 06-08-45-004 > May > 06 > Electrical Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 06-08-45-004 > May > 06 > Electrical Instrument Panel & General Wiring Repair > Page 11497 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 03-08-50-014A > Jan > 06 > Electrical - No Module Communication/DTCs/Warning Lamps Wiring Harness: All Technical Service Bulletins Electrical - No Module Communication/DTCs/Warning Lamps Bulletin No.: 03-08-50-014A Date: January 20, 2006 TECHNICAL Subject: No Communication with Any Modules, Memory Seat May Not Recall, Multiple U-DTCs Set or Instrument Panel Cluster (IPC) Warning Indicators, Crank No Start (Inspect/Repair Affected Wiring Harness) Models: 2003-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL with Front, Individual (Non-Bkt) Seat (RPO AN3) and/or Active Brake Control (Stabilitrak(R)) (RPO JL4) Supercede: This bulletin is being revised to update the various conditions and add the 2004-2006 model years, additional diagnostic and warranty information. Please discard Corporate Bulletin Number 03-08-50-014 (Section 08 - Body & Accessories). Condition Some customers may comment on any of the following conditions: ^ Various IPC Warning indicators are coming on. ^ Driver Information Center (DIC) displays "Unknown Driver". ^ Memory seat may not recall. ^ RKE fobs may be inoperative. ^ Radio or HVAC may shut off. ^ Engine cranks but will not start. Upon investigation, the Technician may find multiple U-DTCs set. Cause On RPO AN3 equipped vehicles, a chafed or pinched seat wiring harness under the driver seat may be a cause of this condition. Because of the routing, a portion of the seat wiring harness may rest on the inboard edge of the seat track or frame. Over time, the harness may be pinched or chafed because of the seat movement. Refer to the above illustration. The illustration shows the inverted position of the seat bottom. The arrow shows the primary location Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 03-08-50-014A > Jan > 06 > Electrical - No Module Communication/DTCs/Warning Lamps > Page 11502 of the possible harness chafing/pinching. Also, on any of the above listed vehicles, the PCM wiring harness may be chafing against the precharge pump bracket or the battery tray. Correction On RPO AN3 vehicles, inspect the routing of the seat wiring harness. Reroute the seat wiring harness and attaching harness fastener (1) to the opposite side of the seat module bracket. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. The seat may have to be removed for ease of access and proper repair of the wiring harness. Inspect the routing of the PCM wiring harness at the precharge pump bracket and the battery tray. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. If any of the above conditions still remain after this repair, refer to SI for further diagnostic information. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 11508 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 11509 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 11510 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 11515 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 11516 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 11517 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 11518 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 11519 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 10-08-45-001B > Oct > 10 > Electrical Information For Electrical Ground Repair > Page 11520 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 09-06-04-034 > Aug > 09 > Fuel System Reduced Engine Power, MIL (Various Codes) > Page 11525 7. Carefully bend up and backwards the FICM wiring harness electrical connectors (1) away from the FICM (4). Note Some of these chafes are very small, possibly the size of a pen tip, but could still cause injector circuit concerns. 8. Inspect the wiring harness for chafing (3) that may result from rubbing at the back of the alternator (2), the alternator bracket or at the FICM harness retaining bracket. If necessary, peel the tape from the area and look for ANY chafes into the wires. ^ If chafing is observed and the conductive portion of the wire IS NOT damaged, apply electrical tape around the wire. ^ If chafing is observed and the conductive portion of the wire IS damaged, then refer to Splicing Copper Wire Using Splice Sleeves in Wiring Repairs in SI. ^ If chafing IS NOT OBSERVED, then refer to the appropriate DTC Diagnostic procedures in SI. 9. Connect the electrical connectors to the FICM. 10. Insulate the harness with suitable material such as conduit or heater hose to prevent a reoccurrence. Note For Silverado and Sierra models only perform Step 11. 11. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 12. Clear the DTCs with a scan tool. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 06-08-45-004 > May > 06 > Electrical Instrument Panel & General Wiring Repair > Page 11530 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 03-08-50-014A > Jan > 06 > Electrical - No Module Communication/DTCs/Warning Lamps > Page 11535 of the possible harness chafing/pinching. Also, on any of the above listed vehicles, the PCM wiring harness may be chafing against the precharge pump bracket or the battery tray. Correction On RPO AN3 vehicles, inspect the routing of the seat wiring harness. Reroute the seat wiring harness and attaching harness fastener (1) to the opposite side of the seat module bracket. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. The seat may have to be removed for ease of access and proper repair of the wiring harness. Inspect the routing of the PCM wiring harness at the precharge pump bracket and the battery tray. Repair the harness as necessary. Refer to Wiring Repairs in the Wiring Systems sub-section of SI. If any of the above conditions still remain after this repair, refer to SI for further diagnostic information. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 11536 Wheel Fastener: Specifications TORQUE SPECIFICATIONS Torque Specifications Wheel Nuts .......................................................................................................................................... ................................................. 190 Nm (140 ft. lbs.) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 11537 Wheel Nut Torque Sequence Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension Wheel Fastener: Service and Repair Front Suspension Wheel Stud Replacement ^ Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel stud from the hub flange using the J 43631. 5. Remove the wheel stud from the hub flange. Installation Procedure 1. Install the new stud into the hub flange hole using firm hand pressure. 2. Install 4 washers to the new wheel stud. 3. Thread a wheel nut onto the new stud with the flat side facing the front hub flange. 4. Tighten the lug nut until the stud contacts the back of the hub flange. 5. Remove the wheel nut. 6. Remove the washers. 7. Install the brake rotor. Refer to Brake Rotor Replacement Front in Disc Brakes. 8. Install the tire and wheel. 9. Remove the safety stands. 10. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 11540 Wheel Fastener: Service and Repair Rear Suspension Wheel Stud Replacement ^ Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor, except dual wheel vehicles. 4. Remove the wheel stud from the axle flange using the J 43631. 5. Remove the axle shaft for vehicles with 9.5 in ring gear. 6. Remove the rear hub assembly for vehicles with 10.5/11.5 in ring gear, with single wheels. 7. Remove the rear axle hub for vehicles with dual wheels. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement. 8. Remove the wheel stud from the axle flange using the J 43631. 9. Remove the wheel stud from the hub flange using the J 43631. 10. Place the hub and rotor assembly in a press to remove the wheel stud. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 11541 1. Install the stud. 2. Install the 4 washers and the lug nut to the stud. 3. Tighten the lug nut in order to draw the stud into the flange until the stud fully seats. 4. Remove the lug nut and the washers. 5. Install the axle shaft for the vehicles with 9.5 in ring gear. 6. Install the rear hub assembly for the vehicles with 10.5/11.5 in ring gear, with single wheels. 7. Install the rear axle hub for vehicles with dual wheels. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement. 8. Install the rotor, except dual wheels. 9. Install the tire and wheel. 10. Remove the safety stands. 11. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Seal > Component Information > Service and Repair Wheel Seal: Service and Repair Wheel Hub, Bearing, and Seal Replacement (4WD) ^ Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 5. Remove the wheel drive shaft nut retaining cover. 6. Important: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Seal > Component Information > Service and Repair > Page 11545 Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent. 8. Remove the wheel hub and the 15-series bearing mounting bolts (4). 9. Remove the wheel hub and bearing (4) mounting bolts, 25/35 series. 10. Remove the wheel hub and bearing and splash shield from the vehicle. 11. Remove the O-ring seal from the steering knuckle bore, 25/35 series. 12. Remove the wheel speed sensor mounting bolt (5). 13. Clean and inspect the O-ring seal, 25/35 series. 14. Replace the seal if the following conditions exist: ^ Nicks ^ Cuts Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Seal > Component Information > Service and Repair > Page 11546 ^ Dry or brittle ^ Compression set Installation Procedure 1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly. 2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent. 3. Install the O-ring (7) to the steering knuckle, the 25/35 series. 4. Notice: Refer to Fastener Notice in Service Precautions. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. ^ Tighten the sensor mounting bolt to 18 Nm (13 ft. lbs.). 5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series. 6. Install the wheel hub and bearing (5) and splash shield (6) to the vehicle, 15 series. 7. Install the wheel hub and bearing mounting bolts, the 15 series. 8. Install the wheel hub and bearing mounting bolts, 25/35 series. ^ Tighten the wheel hub to knuckle bolts to 180 Nm (133 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Seal > Component Information > Service and Repair > Page 11547 9. Install the nut (2) and washer (3) retaining the wheel drive shaft assembly to the wheel hub and bearing. ^ Tighten the nut to 240 Nm (177 ft. lbs.). 10. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. ^ Tighten the brake hose clip bolt to 12 Nm (106 inch lbs.). 11. Install the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes. 12. Install the tire and wheel. 13. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Customer Interest for Accumulator HVAC: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough Accumulator HVAC: Customer Interest A/C - Doesn't Blow Cold Enough Bulletin No.: 02-01-38-007C Date: July 27, 2004 TECHNICAL Subject: Poor A/C Performance - A/C Will Not Blow Cold Enough (Perform A/C System Checks, Replace Accumulator if Necessary) Models: 2002-2004 Chevrolet Silverado 2002-2004 GMC Sierra with 6.6L Diesel Engine (VINs 1, 2 - RPOs LB7, LLY) and Denso A/C Compressor Supercede: This bulletin is being revised to add part numbers for the hose, bracket and insulator to the Parts Information. Please discard Corporate Bulletin Number 02-01-38-007B (Section 01 - HVAC). Condition Some customers may comment on less than desirable A/C performance, especially when the ambient temperature is above 32°C (90°F). Correction Perform the following A/C system checks and replace the accumulator with P/N 89018601, if necessary. This new accumulator requires the accumulator bracket, the accumulator insulator and the A/C suction hose to be replaced also. ^ Check for A/C system leaks. ^ Check the A/C system for proper refrigerant charge. This requires recovering the refrigerant to determine charge in system. Refer to Refrigerant Recovery and Recharging in the HVAC sub-section of the Service Manual. ^ If no leaks were found and the A/C system is charged to specification, replace the accumulator using the procedure listed below. If normal diagnostics do not lead to a correction, then perform the following A/C system checks. 1. Re-calibrate the actuators. 2. Inspect the lower A/C condenser deflector for proper installation. The deflector should be positioned at the lower part of the condenser and extend forward into the top of the front bumper and below the two fresh air intake holes. 3. Check the engine cooling fan clutch for proper operation. 4. If the vehicle is equipped with a front license plate, inspect for proper installation. If the license plate bracket is installed upside down, it will block part of the two fresh air intake holes in the bumper. When the license plate bracket is installed correctly, the writing on the back of the bracket will be upside down. Inspect for material between the radiator and condenser. Remove the top plate to confirm that there is no restriction. A radiator front filled with material will decrease condenser performance. 5. Some improvements have been found by lowering the A/C charge from 0.82 kg (1.8 lbs) to 0.73 kg (1.6 lbs). 6. Check the low pressure cycling switch for proper operation. The low pressure switch opens at 172-234 kPa (25-34 psi) which stops compressor operation and closes when the low side pressure reaches 276-310 kPa (40-45 psi). This enables the compressor to turn back on. Important: Compressor clutch engagement cannot be used to determine the status of the low pressure switch. The low pressure switch is one of several inputs to the HVAC control module for A/C request authorization. A/C request is one of several inputs to the powertrain control module (PCM) that control A/C compressor clutch engagement. Using a scan tool to monitor low pressure switch status while monitoring the low side pressure with the ACR 2000 at the service port and watch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Customer Interest for Accumulator HVAC: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough > Page 11557 the pressure at which the switch opens/closes is imperative to successfully diagnosing the switch. 7. If the A/C performance has not improved after performing the above steps, replace the accumulator with P/N 89018601, using the procedure listed below. This new accumulator also requires the accumulator bracket, accumulator insulator and A/C suction hose to be replaced. Accumulator Replacement 1. Remove the suction hose mounting bolt from the A/C compressor. 2. Remove the suction hose from the compressor. 3. Remove the suction hose nut from the accumulator. 4. Remove the suction hose from the accumulator. 5. Remove the evaporator tube nut from the evaporator. 6. Remove the evaporator tube from the evaporator. 7. Disconnect the electrical connector from the A/C low pressure switch. 8. Remove the nut from the evaporator fitting. 9. Remove the accumulator bracket nut from the retaining stud. 10. Remove the accumulator. 11. Remove the retaining bracket bolt. This bolt must be reused for the new bracket. 12. Remove the insulator. One half of the insulator must be reused. 13. Install the new insulator and one half of the old insulator onto the new accumulator. 14. Install the new retaining bracket and bolt to the accumulator. Do not tighten at this time. 15. Add the PAG oil directly into the new accumulator that was removed during the recovery process plus an additional 90 ml (3 oz). 16. Install the new accumulator. 17. Install the accumulator bracket nut. Tighten Tighten the nut to 9 N.m (80 lb in). 18. Tighten the retaining bracket bolt. Tighten Tighten the nut to 10 N.m (89 lb in). 19. Install the nut to the evaporator fitting. Tighten Tighten the nut to 16 N.m (12 lb ft). 20. Install the evaporator tube to the evaporator. 21. Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N.m (12 lb ft). 22. Install the new suction hose to the accumulator. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Customer Interest for Accumulator HVAC: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough > Page 11558 23. Install the suction hose nut to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft). 24. Connect the electrical connector to the A/C low pressure switch. 25. Install the new suction hose to the compressor. 26. Install the suction hose mounting bolt to the A/C compressor. Tighten Tighten the bolt to 16 N.m (12 lb ft). Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator HVAC: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough Accumulator HVAC: All Technical Service Bulletins A/C - Doesn't Blow Cold Enough Bulletin No.: 02-01-38-007C Date: July 27, 2004 TECHNICAL Subject: Poor A/C Performance - A/C Will Not Blow Cold Enough (Perform A/C System Checks, Replace Accumulator if Necessary) Models: 2002-2004 Chevrolet Silverado 2002-2004 GMC Sierra with 6.6L Diesel Engine (VINs 1, 2 - RPOs LB7, LLY) and Denso A/C Compressor Supercede: This bulletin is being revised to add part numbers for the hose, bracket and insulator to the Parts Information. Please discard Corporate Bulletin Number 02-01-38-007B (Section 01 - HVAC). Condition Some customers may comment on less than desirable A/C performance, especially when the ambient temperature is above 32°C (90°F). Correction Perform the following A/C system checks and replace the accumulator with P/N 89018601, if necessary. This new accumulator requires the accumulator bracket, the accumulator insulator and the A/C suction hose to be replaced also. ^ Check for A/C system leaks. ^ Check the A/C system for proper refrigerant charge. This requires recovering the refrigerant to determine charge in system. Refer to Refrigerant Recovery and Recharging in the HVAC sub-section of the Service Manual. ^ If no leaks were found and the A/C system is charged to specification, replace the accumulator using the procedure listed below. If normal diagnostics do not lead to a correction, then perform the following A/C system checks. 1. Re-calibrate the actuators. 2. Inspect the lower A/C condenser deflector for proper installation. The deflector should be positioned at the lower part of the condenser and extend forward into the top of the front bumper and below the two fresh air intake holes. 3. Check the engine cooling fan clutch for proper operation. 4. If the vehicle is equipped with a front license plate, inspect for proper installation. If the license plate bracket is installed upside down, it will block part of the two fresh air intake holes in the bumper. When the license plate bracket is installed correctly, the writing on the back of the bracket will be upside down. Inspect for material between the radiator and condenser. Remove the top plate to confirm that there is no restriction. A radiator front filled with material will decrease condenser performance. 5. Some improvements have been found by lowering the A/C charge from 0.82 kg (1.8 lbs) to 0.73 kg (1.6 lbs). 6. Check the low pressure cycling switch for proper operation. The low pressure switch opens at 172-234 kPa (25-34 psi) which stops compressor operation and closes when the low side pressure reaches 276-310 kPa (40-45 psi). This enables the compressor to turn back on. Important: Compressor clutch engagement cannot be used to determine the status of the low pressure switch. The low pressure switch is one of several inputs to the HVAC control module for A/C request authorization. A/C request is one of several inputs to the powertrain control module (PCM) that control A/C compressor clutch engagement. Using a scan tool to monitor low pressure switch status while monitoring the low side pressure with the ACR 2000 at the service port and watch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator HVAC: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough > Page 11564 the pressure at which the switch opens/closes is imperative to successfully diagnosing the switch. 7. If the A/C performance has not improved after performing the above steps, replace the accumulator with P/N 89018601, using the procedure listed below. This new accumulator also requires the accumulator bracket, accumulator insulator and A/C suction hose to be replaced. Accumulator Replacement 1. Remove the suction hose mounting bolt from the A/C compressor. 2. Remove the suction hose from the compressor. 3. Remove the suction hose nut from the accumulator. 4. Remove the suction hose from the accumulator. 5. Remove the evaporator tube nut from the evaporator. 6. Remove the evaporator tube from the evaporator. 7. Disconnect the electrical connector from the A/C low pressure switch. 8. Remove the nut from the evaporator fitting. 9. Remove the accumulator bracket nut from the retaining stud. 10. Remove the accumulator. 11. Remove the retaining bracket bolt. This bolt must be reused for the new bracket. 12. Remove the insulator. One half of the insulator must be reused. 13. Install the new insulator and one half of the old insulator onto the new accumulator. 14. Install the new retaining bracket and bolt to the accumulator. Do not tighten at this time. 15. Add the PAG oil directly into the new accumulator that was removed during the recovery process plus an additional 90 ml (3 oz). 16. Install the new accumulator. 17. Install the accumulator bracket nut. Tighten Tighten the nut to 9 N.m (80 lb in). 18. Tighten the retaining bracket bolt. Tighten Tighten the nut to 10 N.m (89 lb in). 19. Install the nut to the evaporator fitting. Tighten Tighten the nut to 16 N.m (12 lb ft). 20. Install the evaporator tube to the evaporator. 21. Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N.m (12 lb ft). 22. Install the new suction hose to the accumulator. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator HVAC: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough > Page 11565 23. Install the suction hose nut to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft). 24. Connect the electrical connector to the A/C low pressure switch. 25. Install the new suction hose to the compressor. 26. Install the suction hose mounting bolt to the A/C compressor. Tighten Tighten the bolt to 16 N.m (12 lb ft). Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Page 11566 Accumulator HVAC: Service and Repair ACCUMULATOR REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the evaporator tube nut from the evaporator. 3. Remove the evaporator tube from the evaporator. 4. Remove the nut from the evaporator tube (3). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Page 11567 5. Disconnect the electrical connector from the A/C low pressure switch. 6. Remove the compressor hose nut from the accumulator. 7. Remove the compressor hose from the accumulator. 8. Remove the nut (2) from the evaporator fitting. 9. Remove the accumulator bracket nut (4) from the retaining stud. 10. Remove the accumulator (3). 11. Remove the retaining bracket bolt (5). 12. Remove the retaining bracket (6) from the accumulator. 13. Remove and discard the O-ring seals. INSTALLATION PROCEDURE 1. Install new O-ring seals. 2. Install the retaining bracket (6) to the accumulator. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the retaining bracket bolt (5). Tighten Tighten the bolt to 10 N.m (89 lb in). 4. Install the accumulator (3). 5. Install the accumulator bracket nut (4). Tighten Tighten the nut to 9 N.m (80 lb in). 6. Install the nut (2) to the evaporator fitting. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Page 11568 Tighten Tighten the nut to 16 N.m (12 lb ft). 7. Install the compressor hose to the accumulator. 8. Install the compressor hose nut to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft). 9. Connect the electrical connector to the A/C low pressure switch. 10. Install the nut to the evaporator tube (3). Tighten Tighten the nut to 25 N.m (18 lb ft). 11. Install the evaporator tube to the evaporator. 12. Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N.m (12 lb ft). 13. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 14. Leak test the fittings of the component using the J 39400-A. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set Air Door Actuator / Motor: Customer Interest A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set > Page 11578 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set Air Door Actuator / Motor: All Technical Service Bulletins A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set > Page 11584 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Page 11585 Air Door Actuator / Motor: Locations Air Temperature Sensors - Lower Left Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Page 11586 Air Temperature Sensors - Lower Right Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Page 11587 HVAC Module Assembly - Bottom Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Page 11588 HVAC Module Assembly - Top Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > HVAC System - Automatic Air Door Actuator / Motor: Diagrams HVAC System - Automatic Mode Actuator Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 11591 Recirculation Actuator Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 11592 Air Temperature Actuator - Left Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 11593 Air Temperature Actuator - Right Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 11594 Air Door Actuator / Motor: Diagrams HVAC System - Manual Air Temperature Actuator - Left Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 11595 Air Temperature Actuator - Right Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 11596 Mode Actuator Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > HVAC System - Automatic > Page 11597 Recirculation Actuator Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Page 11598 Air Door Actuator / Motor: Description and Operation HVAC CONTROL MODULE Mode Actuator The mode actuator is a 5-wire bi-directional electric motor that incorporates a feedback potentiometer. Ignition 3 voltage, low reference, control, 5-volt reference and position signal circuits enable the actuator to operate. The control circuit uses either a 0, 2.5 or 5-volt signal to command the actuator movement. When the actuator is at rest, the control circuit value is 2.5 volts. A 0 or 5-volt control signal commands the actuator movement in opposite directions. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door position signal between 0.5 volts. The HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range. When the module sets a commanded, or targeted value, the control signal is changed to either 0 or 5 volts depending upon the direction that the actuator needs to rotate to reach the commanded value. As the actuator shaft rotates the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module changes the control signal to 2.5 volts. AIR DISTRIBUTION Mode Actuator The mode actuator is an electronic stepper motor with feedback potentiometers. The HVAC control module sends different signals to the mode door actuator through the mode door control circuit. Zero volts drives the actuator in one direction while 5 volts moves the actuator in the opposite direction. When the actuator receives 2.5 volts, the actuator rotation stops. A 5-volt reference signal is sent out over the 5-volt reference circuit to the mode actuator. When you select a desired mode setting, logic determines the value of the mode actuator signals. The HVAC control module's software uses this reference voltage in order to determine the position of the mode actuator through the mode door position signal circuit. The motor moves the mode door to the desired position. AIR TEMPERATURE ACTUATOR The air temperature actuators are a 5-wire bi-directional electric motor that incorporates a feedback potentiometer. Ignition 3 voltage, low reference, control, 5-volt reference, and position signal circuits enable the actuator to operate. The control circuit uses either a 0, 2.5, or 5-volt signal to command the actuator movement. When the actuator is at rest, the control circuit value is 2.5 volts. A 0 or 5-volt control signal commands the actuator movement in opposite directions. When the actuator shaft rotates, the potentiometers adjustable contact changes the door position signal between 0.5 volts. The HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal voltage is converted to a 0-255 count range. When the module sets a commanded, or targeted, value, the control signal is changed to either 0 or 5 volts depending upon the direction that the actuator needs to rotate to reach the commanded value. As the actuator shaft rotates, the changing position signal is sent to the module. Once the position signal and the commanded value are the same, the module changes the control signal to 2.5 volts. RECIRCULATION ACTUATOR The HVAC control module controls the air intake through the recirculation actuator. Recirculation is not available when the mode is in defrost. When the mode is in defog, Recirculation will only be available for 10 minutes. The operator must activate the blower for Recirculation operation. The A/C high-pressure recirculation switch can cause the HVAC system to recirculate air. If the recirculation switch is pressed into the ON position when the mode switch is in an unavailable mode position, then the recirculation switch LED will flash 3 times. When the high side pressure reaches 2206-2620 kPa (320-380 psi), the PCM will place the HVAC system in recirculation mode. The high side pressure is lowered when the inside air cools the refrigerant within the A/C evaporator. When the high-side pressure reaches 1447-1861 kPa (210-270 psi), the PCM will place the HVAC system out of recirculation mode. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator Recalibration - HVAC Air Door Actuator / Motor: Service and Repair Actuator Recalibration - HVAC RE-CALIBRATING ACTUATORS When replacing the HVAC control module it will be necessary to allow the HVAC control module to perform a calibration process. When installing the HVAC control module be sure to perform the following: IMPORTANT: Do not adjust any controls on the HVAC control module while the HVAC control module is self-calibrating. If interrupted, improper HVAC performance will result. 1. Place the ignition switch to the OFF position. 2. Disconnect the scan tool. 3. Install the HVAC control module. 4. Connect all previously disconnected components. 5. Start the vehicle. 6. Wait 40 seconds for the HVAC control module to self-calibrate. 7. Verify that no DTCs have set as current DTCs. When replacing the HVAC actuator it will be necessary to allow the HVAC control module to perform a calibration process. When installing the HVAC actuator be sure to perform one of the following: IMPORTANT: Do not adjust any controls on the HVAC control module while the HVAC control module is self-calibrating. If interrupted, improper HVAC performance will result. Preferred Method (w/ Scan Tool) 1. Clear all DTCs. 2. Place the ignition switch in the OFF position. 3. Install the HVAC actuator. 4. Connect all previously disconnected components. 5. Start the vehicle. 6. With the scan tool, initiate the Motor Re-calibration feature of the Heating and Air Conditioning Special Functions menu. 7. Verify that no DTCs have set as current DTCs. IMPORTANT: Do not adjust any controls on the HVAC control module while the HVAC control module is self-calibrating. If interrupted, improper HVAC performance will result. Alternate Method (w/o Scan Tool) 1. Clear all DTCs. 2. Place the ignition switch to the OFF position. 3. Install the HVAC actuator. 4. Connect all previously disconnected components. 5. Remove the HVAC/ECAS fuse for a minimum of 10 seconds. 6. Install the HVAC/ECAS fuse. 7. Start the vehicle. 8. Wait 40 seconds for the HVAC control module to self-calibrate. 9. Verify that no DTCs have set as current DTCs. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator Recalibration - HVAC > Page 11601 Air Door Actuator / Motor: Service and Repair HVAC System - Automatic Air Temperature Actuator Replacement - Left AIR TEMPERATURE ACTUATOR REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the I/P insulator panel. 2. Disconnect the electrical connector (1) from the left air temperature actuator (2). 3. Remove the screws from the left air temperature actuator (2). 4. Remove the left air temperature actuator (2) from the HVAC module assembly (3). INSTALLATION PROCEDURE 1. Install the left air temperature actuator (2) to the HVAC module assembly (3). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the left air temperature actuator (2). Tighten Tighten the screws to 2 N.m (18 lb ft). 3. Install the electrical connector (1) to the left air temperature actuator (2). 4. Install the I/P insulator panel. 5. Reprogram the left air temperature actuator. Refer to Re-Calibrating Actuators. See: Testing and Inspection/Component Tests and General Diagnostics Air Temperature Actuator Replacement - Right Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator Recalibration - HVAC > Page 11602 AIR TEMPERATURE ACTUATOR REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the I/P carrier. 2. Disconnect the electrical connector (4) from the right air temperature actuator (3). 3. Remove the screws from the right air temperature actuator (3). 4. Remove the right air temperature actuator (3) from the HVAC module assembly (2). INSTALLATION PROCEDURE 1. Install the right air temperature actuator (3) from the HVAC module assembly (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the right air temperature actuator (3). Tighten Tighten the screws to 2 N.m (18 lb in). 3. Connect the electrical connector to the right air temperature actuator. 4. Install the I/P carrier. 5. Reprogram the air temperature actuator. Refer to Re-Calibrating Actuators. See: Testing and Inspection/Component Tests and General Diagnostics Mode Actuator Replacement (With RPO Code D07) MODE ACTUATOR REPLACEMENT (W/ D07) REMOVAL PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator Recalibration - HVAC > Page 11603 1. Remove the floor air outlet duct extension (1) from the floor duct (2). 2. Remove the center console. 3. Remove the screws from the center console duct. 4. Remove the center console duct. 5. Disconnect the electrical connection from the mode actuator (10). 6. Remove the mode actuator mounting screws from the HVAC module. 7. Remove the mode actuator as an assembly with the actuator cam. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator Recalibration - HVAC > Page 11604 1. Install the mode actuator as an assembly with the actuator cam. - Line up the heater/defroster valve lever with the mode actuator cam slot. - Line up the A/C valve lever with the mode actuator cam. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the mode actuator mounting screws to the HVAC module. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connection at the mode actuator (10). 4. Install the center console duct. 5. Install the screws to the center console duct. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator Recalibration - HVAC > Page 11605 Tighten Tighten the screws to 1.6 N.m (14 lb in). 6. Install the center console. 7. Install the floor air outlet duct extension (1) to the floor air duct (2). Mode Actuator(Without RPO Code D07) MODE ACTUATOR REPLACEMENT (W/O D07) REMOVAL PROCEDURE 1. Remove the floor air outlet duct extension (1) from the floor duct (2). 2. Remove the Body Control Module. 3. Disconnect the electrical connection at the mode actuator (10). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator Recalibration - HVAC > Page 11606 4. Remove the mode actuator mounting screws from the HVAC module. 5. Remove the mode actuator as an assembly with the actuator cam. INSTALLATION PROCEDURE 1. Install the mode actuator as an assembly with the actuator cam. - Line up the heater/defroster lever with the mode actuator cam slot. - Line up the A/C lever with the mode actuator cam. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the mode actuator mounting screws to the HVAC module. Tighten Tighten the screws to 1.6 N.m (14 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator Recalibration - HVAC > Page 11607 3. Connect the electrical connection at the mode actuator (10). 4. Install the Body Control Module. 5. Install the floor air outlet duct extension (1) to the floor air duct (2). Recirculation Actuator RECIRCULATION ACTUATOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the air distribution duct. 2. Disconnect the electrical connection from the recirculation actuator (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator Recalibration - HVAC > Page 11608 3. Remove the recirculation actuator retaining screws. 4. Remove the recirculation actuator. INSTALLATION PROCEDURE 1. Install the recirculation actuator. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the recirculation actuator retaining screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator Recalibration - HVAC > Page 11609 3. Connect the electrical connector to the recirculation actuator (1). 4. Install the air distribution duct Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator Recalibration - HVAC > Page 11610 Air Door Actuator / Motor: Service and Repair HVAC System - Manual Air Temperature Actuator AIR TEMPERATURE ACTUATOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the IP insulator. 2. Disconnect the electrical connector (8) from the air temperature actuator (9). 3. Remove the air temperature actuator retaining screws. 4. Remove the air temperature actuator. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator Recalibration - HVAC > Page 11611 INSTALLATION PROCEDURE 1. Install the air temperature actuator. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the air temperature actuator retaining screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector (8) to the air temperature actuator (9). 4. Install the IP insulator. Air Temperature Actuator Replacement - Left Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator Recalibration - HVAC > Page 11612 AIR TEMPERATURE ACTUATOR REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the I/P insulator panel. 2. Disconnect the electrical connector (1) from the left air temperature actuator (2). 3. Remove the screws from the left air temperature actuator (2). 4. Remove the left air temperature actuator (2) from the HVAC module assembly (3). INSTALLATION PROCEDURE 1. Install the left air temperature actuator (2) to the HVAC module assembly (3). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the left air temperature actuator (2). Tighten Tighten the screws to 2 N.m (18 lb ft). 3. Install the electrical connector (1) to the left air temperature actuator (2). 4. Install the I/P insulator panel. 5. Reprogram the air temperature actuator. Refer to Re-Calibrating Actuators. See: Testing and Inspection/Component Tests and General Diagnostics Air Temperature Actuator Replacement - Right AIR TEMPERATURE ACTUATOR REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the I/P carrier. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator Recalibration - HVAC > Page 11613 2. Disconnect the electrical connector (4) from the right air temperature actuator (3). 3. Remove the screws from the right air temperature actuator (3). 4. Remove the right air temperature actuator (3) from the HVAC module assembly (2). INSTALLATION PROCEDURE 1. Install the right air temperature actuator (3) from the HVAC module assembly (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the right air temperature actuator (3). Tighten Tighten the screws to 2 N.m (18 lb in). 3. Connect the electrical connector to the right air temperature actuator. 4. Install the I/P carrier. 5. Reprogram the air temperature actuator. Refer to Re-Calibrating Actuators. See: Testing and Inspection/Component Tests and General Diagnostics Mode Actuator (With RPO Code D07) MODE ACTUATOR REPLACEMENT (W/ D07) REMOVAL PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator Recalibration - HVAC > Page 11614 1. Remove the floor air outlet duct extension (1) from the floor duct (2). 2. Remove the center console. 3. Remove the screws from the center console duct. 4. Remove the center console duct. 5. Disconnect the electrical connection from the mode actuator (10). 6. Remove the mode actuator mounting screws from the HVAC module. 7. Remove the mode actuator as an assembly with the actuator cam. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator Recalibration - HVAC > Page 11615 1. Install the mode actuator as an assembly with the actuator cam. - Line up the heater/defroster valve lever with the mode actuator cam slot. - Line up the A/C valve lever with the mode actuator cam NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the mode actuator mounting screws to the HVAC module. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connection at the mode actuator (10). 4. Install the center console duct. 5. Install the screws to the center console duct. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator Recalibration - HVAC > Page 11616 Tighten Tighten the screws to 1.6 N.m (14 lb in). 6. Install the center console. 7. Install the floor air outlet duct extension (1) to the floor air duct (2). Mode Actuator (Without RPO Code D07) MODE ACTUATOR REPLACEMENT (W/O D07) REMOVAL PROCEDURE 1. Remove the floor air outlet duct extension (1) from the floor duct (2). 2. Disconnect the electrical connection at the mode actuator (10). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator Recalibration - HVAC > Page 11617 3. Remove the mode actuator mounting screws from the HVAC module. 4. Remove the mode actuator as an assembly with the actuator cam. INSTALLATION PROCEDURE 1. Install the mode actuator as an assembly with the actuator cam. - Line up the heater/defroster valve lever with the mode actuator cam slot. - Line up the A/C valve lever with the mode actuator cam. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the mode actuator mounting screw to the HVAC module. Tighten Tighten the screw to 1.6 N.m (14 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator Recalibration - HVAC > Page 11618 3. Connect the electrical connection at the mode actuator (10). 4. Install the floor air outlet duct extension (1) to the floor air duct (2). Recirculation Actuator (Delphi) RECIRCULATION ACTUATOR REPLACEMENT (DELPHI) REMOVAL PROCEDURE 1. Remove the air distribution duct. 2. Disconnect the electrical connection from the recirculation actuator (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator Recalibration - HVAC > Page 11619 3. Remove the recirculation actuator retaining screws. 4. Remove the recirculation actuator. INSTALLATION PROCEDURE 1. Install the recirculation actuator. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the recirculation actuator retaining screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator Recalibration - HVAC > Page 11620 3. Connect the electrical connector to the recirculation actuator (1). 4. Install the air distribution duct. Recirculation Actuator (Visteon) RECIRCULATION ACTUATOR REPLACEMENT (VISTEON) REMOVAL PROCEDURE 1. Remove the HVAC module assembly. 2. Remove the screws from the evaporator core cover (1). 3. Remove the evaporator core cover (1) from the HVAC module assembly (2). 4. Remove the screws from the recirculation actuator (1). 5. Remove the recirculation actuator (1) from the HVAC module assembly (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator Recalibration - HVAC > Page 11621 INSTALLATION PROCEDURE 1. Install the recirculation actuator (1) to the HVAC module assembly (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the recirculation actuator (1). Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the evaporator core cover (1) to the HVAC module assembly (2). 4. Install the screws to the evaporator core cover (1). Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the HVAC module assembly. 6. Reprogram the recirculation actuator. Refer to Re-Calibrating Actuators. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair Air Door Cable: Service and Repair MODE CONTROL CABLE REPLACEMENT REMOVAL PROCEDURE 1. Remove the radio. 2. Remove the heater control assembly. 3. Disconnect the mode cable from the heater/ventilation module. 4. Remove the mode cable from the IP carrier. INSTALLATION PROCEDURE 1. Install the mode cable to the IP carrier. 2. Connect the mode cable to the heater/ventilation module. 3. Install the heater control assembly. 4. Install the radio. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement Air Duct: Service and Repair Air Distributor Duct Replacement AIR DISTRIBUTOR DUCT REPLACEMENT REMOVAL PROCEDURE 1. Remove the IP carrier. 2. Remove the air distribution duct retaining screws. 3. Remove the air distribution duct. INSTALLATION PROCEDURE 1. Install the air distribution duct. 2. Install the air distribution duct retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 4. Install the IP carrier. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 11629 Air Duct: Service and Repair Air Outlet Duct Replacement - Floor, LH AIR OUTLET DUCT REPLACEMENT - FLOOR, LH REMOVAL PROCEDURE 1. Remove the push pin (5) from the left floor air outlet duct (4). 2. Remove the left floor duct (1) from the HVAC module (2). INSTALLATION PROCEDURE 1. Install the left floor air outlet duct (1) to the HVAC module (2). 2. Install the push pin (2) to the left floor air outlet duct. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 11630 Air Duct: Service and Repair Air Outlet Duct Replacement - Floor, RH AIR OUTLET DUCT REPLACEMENT - FLOOR, RH REMOVAL PROCEDURE 1. Remove the right closeout/insulator panel. 2. Remove the screw from the right floor air outlet duct (3). 3. Remove the right floor air outlet duct (3) from the HVAC module (2). INSTALLATION PROCEDURE 1. Install the right floor air outlet duct (3) to the HVAC module (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screw to the right floor air outlet duct (3). Tighten Tighten the screw to 1.6 N.m (14 lb in). 3. Install the right closeout/insulator panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Deflector Replacement - Instrument Panel Air - Center Air Register: Service and Repair Deflector Replacement - Instrument Panel Air - Center DEFLECTOR REPLACEMENT - INSTRUMENT PANEL AIR - CENTER REMOVAL PROCEDURE 1. Remove the instrument panel (I/P) bezel. 2. Remove the I/P trim panel. 3. Remove the deflector mounting screws. 4. Remove the deflector from the I/P. INSTALLATION PROCEDURE 1. Install the deflector to the I/P. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the deflector mounting screws. Tighten Tighten the screw to 1.6 N.m (14 lb in). 3. Install the I/P trim panel. 4. Install the I/P bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Deflector Replacement - Instrument Panel Air - Center > Page 11635 Air Register: Service and Repair Deflector Replacement - Instrument Panel Air - Left DEFLECTOR REPLACEMENT - INSTRUMENT PANEL AIR - LEFT REMOVAL PROCEDURE 1. Remove the instrument panel (I/P) bezel. 2. Remove the knee bolster. 3. Remove the air deflector housing from the I/P by prying it out. 4. Disconnect the electrical connectors. 5. Remove the air deflector screws. 6. Remove the air deflector from the housing. INSTALLATION PROCEDURE 1. Install the air deflector to the housing. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connectors. 4. Install the air deflector assembly to the I/P. 5. Remove the knee bolster. 6. Install the I/P bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Deflector Replacement - Instrument Panel Air - Center > Page 11636 Air Register: Service and Repair Deflector Replacement - Instrument Panel Air - Right DEFLECTOR REPLACEMENT - INSTRUMENT PANEL AIR - RIGHT REMOVAL PROCEDURE 1. Use a flat blade tool in order to remove the deflector from the instrument panel. 2. Remove the deflector. INSTALLATION PROCEDURE 1. Align the deflector into the opening in the instrument panel. 2. Push the deflector into the instrument panel until the deflector snaps into place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Air Temperature Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 11640 Ambient Air Temperature Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 11641 Ambient Temperature Sensor / Switch HVAC: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2-wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: Ambient Air Temperature Sensor - Inside Air Temperature Sensor Assembly - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Air Temperature Sensor A signal and a low-reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0.5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated under the above conditions. The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 11642 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the Park/Turn Signal. 2. Disconnect the electrical connector from the ambient air temperature sensor (3). 3. Remove the ambient air temperature sensor (3). INSTALLATION PROCEDURE 1. Install the ambient air temperature sensor (3). 2. Connect the electrical connector to the ambient air temperature sensor (3). 3. Install the Park/Turn Signal. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Blower Motor: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11648 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11649 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11650 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11651 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11652 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11653 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11654 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11655 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11656 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11657 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11658 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11659 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11660 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11661 Auxiliary Blower Motor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11662 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11663 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11664 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11665 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11666 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11667 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11668 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11669 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11670 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11671 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11672 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11673 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11674 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11675 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11676 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11677 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11678 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11679 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11680 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11681 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11682 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11683 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11684 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11685 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11686 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11687 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11688 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11689 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11690 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11691 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11692 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11693 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11694 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11695 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Blower Motor Impeller > Component Information > Service and Repair Blower Motor Impeller: Service and Repair BLOWER MOTOR IMPELLER REPLACEMENT (VISTEON) REMOVAL PROCEDURE 1. Remove the sound insulator panel. 2. Disconnect the electrical connector (2) from the blower motor (1). 3. Remove the screws from the blower motor (1). 4. Remove the blower motor (1) from the HVAC module (3). 5. Remove the retainer from the blower motor impeller. Discard the retainer. 6. Remove the blower motor impeller from the blower motor (1). INSTALLATION PROCEDURE 1. Install the blower motor impeller to the blower motor (1). 2. Install the new retainer to the blower motor impeller. 3. Install the blower motor (1) to the HVAC module (3). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the blower motor (1). Tighten Tighten the screws to 2 N.m (18 lb in). 5. Connect the electrical connector (2) to the blower motor (1). 6. Install the sound insulator panel Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Recalls: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously Blower Motor Resistor: Recalls Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Recalls: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 11707 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Recalls: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 11708 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Customer Interest: > 05-01-38-012C > Nov > 06 > A/C - Blower Motor Inop. or Works On Low Speed Only Blower Motor Resistor: Customer Interest A/C - Blower Motor Inop. or Works On Low Speed Only Bulletin No.: 05-01-38-012C Date: November 02, 2006 TECHNICAL Subject: EI05082 - Loss of Blower Motor Speeds Except for Low Speed or Inoperative (Replace Blower Motor Resistor and Resistor Module Connector) Models: 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2007 Chevrolet Silverado (Classic) Built Prior to September 1, 2006 2004-2006 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL 2007 GMC Sierra (Classic) Built Prior to September 1, 2006 with HVAC System AC Front, Manual Temp Control (RPO CJ3) or Heater Only (RPO C42) Supercede: This bulletin is being revised to clarify the Warranty Information. Please discard Corporate Bulletin Number 05-01-38-012B (Section 01 - HVAC). Condition Some customers may comment that the blower will only work on low speeds or has become inoperative. Correction REPLACE THE BLOWER MOTOR RESISTOR AND RESISTOR MODULE CONNECTOR. Replace the blower motor resistor and module connector using the following procedure: Remove the blower fuse. Fullsize Trucks and Utility Vehicles - Htr A/C & HVAC 1 fuses Midsize Utility Vehicles - Blower Fuse 35 located in the Underhood Fuse Block Lower the hush panel or close-out panel enough to gain access to the resistor module connector. Disconnect the connector from the resistor module. Remove the tape from the wiring harness to expose the wiring. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Customer Interest: > 05-01-38-012C > Nov > 06 > A/C - Blower Motor Inop. or Works On Low Speed Only > Page 11714 Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Tip Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Install the new connector. Use the yellow splice sleeves provided with the connector. Install new blower motor resistor. Reinstall the fuse or connector block. Test the blower motor to make sure all speeds are functional. Reinstall the hush panel/close-out panel. Parts Information Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Customer Interest: > 05-01-38-012C > Nov > 06 > A/C - Blower Motor Inop. or Works On Low Speed Only > Page 11715 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Resistor: > 11046 > Apr > 11 > Campaign HVAC Blower Not Functional Runs Continuously Blower Motor Resistor: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Resistor: > 11046 > Apr > 11 > Campaign HVAC Blower Not Functional Runs Continuously > Page 11721 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Resistor: > 11046 > Apr > 11 > Campaign HVAC Blower Not Functional Runs Continuously > Page 11722 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Resistor: > 05-01-38-012C > Nov > 06 > A/C Blower Motor Inop. or Works On Low Speed Only Blower Motor Resistor: All Technical Service Bulletins A/C - Blower Motor Inop. or Works On Low Speed Only Bulletin No.: 05-01-38-012C Date: November 02, 2006 TECHNICAL Subject: EI05082 - Loss of Blower Motor Speeds Except for Low Speed or Inoperative (Replace Blower Motor Resistor and Resistor Module Connector) Models: 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2007 Chevrolet Silverado (Classic) Built Prior to September 1, 2006 2004-2006 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL 2007 GMC Sierra (Classic) Built Prior to September 1, 2006 with HVAC System AC Front, Manual Temp Control (RPO CJ3) or Heater Only (RPO C42) Supercede: This bulletin is being revised to clarify the Warranty Information. Please discard Corporate Bulletin Number 05-01-38-012B (Section 01 - HVAC). Condition Some customers may comment that the blower will only work on low speeds or has become inoperative. Correction REPLACE THE BLOWER MOTOR RESISTOR AND RESISTOR MODULE CONNECTOR. Replace the blower motor resistor and module connector using the following procedure: Remove the blower fuse. Fullsize Trucks and Utility Vehicles - Htr A/C & HVAC 1 fuses Midsize Utility Vehicles - Blower Fuse 35 located in the Underhood Fuse Block Lower the hush panel or close-out panel enough to gain access to the resistor module connector. Disconnect the connector from the resistor module. Remove the tape from the wiring harness to expose the wiring. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Resistor: > 05-01-38-012C > Nov > 06 > A/C Blower Motor Inop. or Works On Low Speed Only > Page 11727 Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Tip Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Install the new connector. Use the yellow splice sleeves provided with the connector. Install new blower motor resistor. Reinstall the fuse or connector block. Test the blower motor to make sure all speeds are functional. Reinstall the hush panel/close-out panel. Parts Information Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Resistor: > 05-01-38-012C > Nov > 06 > A/C Blower Motor Inop. or Works On Low Speed Only > Page 11728 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 05-01-38-012C > Nov > 06 > A/C Blower Motor Inop. or Works On Low Speed Only Blower Motor Resistor: All Technical Service Bulletins A/C - Blower Motor Inop. or Works On Low Speed Only Bulletin No.: 05-01-38-012C Date: November 02, 2006 TECHNICAL Subject: EI05082 - Loss of Blower Motor Speeds Except for Low Speed or Inoperative (Replace Blower Motor Resistor and Resistor Module Connector) Models: 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2007 Chevrolet Silverado (Classic) Built Prior to September 1, 2006 2004-2006 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL 2007 GMC Sierra (Classic) Built Prior to September 1, 2006 with HVAC System AC Front, Manual Temp Control (RPO CJ3) or Heater Only (RPO C42) Supercede: This bulletin is being revised to clarify the Warranty Information. Please discard Corporate Bulletin Number 05-01-38-012B (Section 01 - HVAC). Condition Some customers may comment that the blower will only work on low speeds or has become inoperative. Correction REPLACE THE BLOWER MOTOR RESISTOR AND RESISTOR MODULE CONNECTOR. Replace the blower motor resistor and module connector using the following procedure: Remove the blower fuse. Fullsize Trucks and Utility Vehicles - Htr A/C & HVAC 1 fuses Midsize Utility Vehicles - Blower Fuse 35 located in the Underhood Fuse Block Lower the hush panel or close-out panel enough to gain access to the resistor module connector. Disconnect the connector from the resistor module. Remove the tape from the wiring harness to expose the wiring. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 05-01-38-012C > Nov > 06 > A/C Blower Motor Inop. or Works On Low Speed Only > Page 11734 Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Tip Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Install the new connector. Use the yellow splice sleeves provided with the connector. Install new blower motor resistor. Reinstall the fuse or connector block. Test the blower motor to make sure all speeds are functional. Reinstall the hush panel/close-out panel. Parts Information Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 05-01-38-012C > Nov > 06 > A/C Blower Motor Inop. or Works On Low Speed Only > Page 11735 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously Blower Motor Resistor: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 11741 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 11742 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Page 11743 Blower Motor Resistor Assembly Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Replacement Blower Motor Resistor: Service and Repair Blower Motor Resistor Replacement BLOWER MOTOR RESISTOR REPLACEMENT REMOVAL PROCEDURE 1. If equipped, remove the IP sound insulator. 2. Disconnect the electrical connection from the blower motor. 3. Disconnect the electrical connection from the blower motor resistor. 4. Remove the blower motor resistor retaining screws. 5. Remove the blower motor resistor. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Replacement > Page 11746 1. Install the blower motor resistor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the blower motor resistor retaining screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connection to the blower motor resistor. 4. Connect the electrical connection to the blower motor. 5. If equipped, install the IP sound insulator. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Replacement > Page 11747 Blower Motor Resistor: Service and Repair Blower Motor Replacement (Delphi) BLOWER MOTOR REPLACEMENT (DELPHI) REMOVAL PROCEDURE 1. If equipped, remove the sound insulator panel. 2. Remove the blower motor insulating cover screws. 3. Disconnect the electrical connector from the blower motor. 4. Remove the blower motor insulating cover. 5. Pull the retaining tab down while turning the blower motor counterclockwise in order to disengage the blower motor from the heater/ventilation module. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Replacement > Page 11748 6. Remove the blower motor. INSTALLATION PROCEDURE 1. Install the blower motor. 2. Install the blower motor to the heater/ventilation module. Turn the blower assembly clockwise until the retaining tab locks into place. 3. Install the blower motor insulating cover. 4. Connect the electrical connector to the blower motor. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the blower motor insulating cover screws. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Replacement > Page 11749 Tighten Tighten the screws to 1.6 N.m (14 lb in). 6. If equipped, install the sound insulator panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Replacement > Page 11750 Blower Motor Resistor: Service and Repair Blower Motor Replacement (Visteon) BLOWER MOTOR REPLACEMENT (VISTEON) REMOVAL PROCEDURE 1. Remove the sound insulator panel. 2. Disconnect the electrical connector (2) from the blower motor (1). 3. Remove the screws from the blower motor (1). 4. Remove the blower motor (1) from the HVAC module (3). 5. Remove the retainer from the blower motor impeller. Discard the retainer. 6. Remove the blower motor impeller from the blower motor (1). INSTALLATION PROCEDURE 1. Install the blower motor impeller to the blower motor (1). 2. Install the new retainer to the blower motor impeller. 3. Install the blower motor (1) to the HVAC module (3). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the blower motor (1) Tighten Tighten the screws to 2 N.m (18 lb in). 5. Connect the electrical connector (2) to the blower motor (1). 6. Install the sound insulator panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Locations Cabin Air Filter: Locations This vehicle does not have a factory installed Cabin Air Filter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Locations > Page 11754 Cabin Air Filter: Service and Repair This Article has been updated by bulletin #PIT3330, dated December 22, 2004. Condition/Concern: A customer may inquire about the availability of the passenger compartment air filter. Recommendation/Instructions: Starting in 2003 model year, the passenger compartment air filter is no longer available as a factory option. With the redesigned HVAC case, there is no longer a cavity for the filter. The GM parts catalog indicates there is a replacement filter available; however, there is no provision for it. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Diagrams Inside Air Temperature Sensor Assembly Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Diagrams > Page 11758 Cabin Temperature Sensor / Switch: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2-wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: Ambient Air Temperature Sensor - Inside Air Temperature Sensor Assembly - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Air Temperature Sensor A signal and a low-reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0.5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated under the above conditions. The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Diagrams > Page 11759 Cabin Temperature Sensor / Switch: Service and Repair INSIDE AIR TEMPERATURE SENSOR ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the left windshield garnish molding. 2. Remove the left center pillar assist handle. 3. Remove the left center pillar garnish molding. 4. Remove the left sunshade. 5. Gently pull down the headliner. 6. Disconnect the electrical connector from the inside air temperature sensor. 7. Partially remove the inside air temperature sensor from the headliner. 8. Remove the sensor grille from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. INSTALLATION PROCEDURE 1. Install the new sensor grille to the headliner. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Diagrams > Page 11760 2. Install the inside air temperature sensor to the headliner and sensor grille. 3. Connect the electrical connector to the inside air temperature sensor. 4. Install the left sunshade. 5. Install the left center pillar garnish molding. 6. Install the left center assist handle. 7. Install the left windshield garnish molding. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Duct > Component Information > Service and Repair Cabin Ventilation Duct: Service and Repair Pressure Relief Valve Replacement Removal Procedure Use a flat-bladed tool to pry the pressure release valve from the cab back panel. Remove the pressure relief valve from the vehicle. Installation Procedure Align the pressure relief valve into the opening of the rear cab. Press the Pressure Relief Valve into the Cab Back Panel until the locking tabs are fully seated. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement Removal Procedure Use a flat-bladed tool to pry the pressure release valve from the cab back panel. Remove the pressure relief valve from the vehicle. Installation Procedure Align the pressure relief valve into the opening of the rear cab. Press the Pressure Relief Valve into the Cab Back Panel until the locking tabs are fully seated. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > HVAC System - Manual A/C Compressor Clutch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > HVAC System - Manual > Page 11772 A/C Compressor Clutch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair Compressor Clutch Hub: Service and Repair COMPRESSOR CLUTCH PLATE/HUB ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the engine protection shield. 3. Install a ratchet into the air conditioning (A/C) belt tensioner adapter opening. 4. Rotate the A/C belt tensioner clockwise in order to relieve the tension on the belt. 5. Remove the A/C belt from the A/C compressor. 6. Slowly release the tension on the A/C belt tensioner. 7. Remove the clutch plate retaining bolt (1). 8. Remove the clutch plate assembly (2). 9. Remove the clutch hub/bearing snap ring (3). 10. Remove the clutch hub/bearing assembly (4). 11. Remove the snap ring (5) from the clutch coil (6). 12. Remove the clutch coil (6) from the A/C compressor (7). INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > Page 11776 1. Install the clutch coil (6) to the A/C compressor (7). 2. Install the snap ring (5) to the clutch coil (6). 3. Install the clutch hub/bearing assembly (4). 4. Install the clutch hub/bearing snap ring (3). 5. Install the clutch plate assembly (2). NOTE: Refer to Fastener Notice in Service Precautions. 6. Install the clutch plate retaining bolt (1). Tighten Tighten the bolt to 18 N.m (13 lb ft). 7. Install a ratchet into the A/C belt tensioner adapter opening. 8. Rotate the A/C belt tensioner clockwise in order to relieve the tension on the belt. 9. Install the A/C belt to the A/C compressor. 10. Slowly release the tension on the A/C belt tensioner. 11. Remove the ratchet from the A/C belt tensioner. 12. Install the engine protection shield. 13. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Service and Repair Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover from the underhood convenience center (1). 2. Remove the compressor relay (2). INSTALLATION PROCEDURE 1. Install the compressor relay (2). 2. Install the cover to the underhood convenience center (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair Condenser HVAC: Service and Repair CONDENSER REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the grille. 3. Remove the tie bar to radiator brace bolts (1). Access the bolts from the rear of the upper radiator support. 4. Remove the lower bolts from the hood latch support bracket. 5. Remove the compressor discharge hose assembly bolt from the condenser. 6. Disconnect the compressor discharge hose assembly from the condenser. 7. Remove the evaporator tube nut from the condenser. 8. Disconnect the evaporator tube from the condenser. 9. Remove the insulator retainer bolts and the upper insulator retainers. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Page 11783 10. Remove the condenser from the vehicle. INSTALLATION PROCEDURE IMPORTANT: If replacing the condenser, add the refrigerant oil to the condenser. Refer to Refrigerant System Capacities for system capacity information. 1. Install the condenser to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the upper insulator retainers and the insulator retainer bolts. Tighten Tighten the bolts to 2.4 N.m (21 lb in). 3. Connect the evaporator tube to the condenser using new sealing washers. 4. Install the evaporator tube nut to the condenser. Tighten Tighten the evaporator tube nut to 16 N.m (12 lb ft). 5. Connect the compressor discharge hose to the condenser using new sealing washers. 6. Install the compressor discharge hose nut to the condenser Tighten Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Page 11784 Tighten the compressor discharge hose nut to 16 N.m (12 lb ft). 7. Install the lower bolts to the hood latch support bracket. Tighten Tighten the compressor discharge hose nut to 9 N.m (80 lb in). 8. Install the tie bar to radiator brace bolts (1). Access the bolts from the rear of the upper radiator support. Tighten Tighten the compressor discharge hose nut to 9 N.m (80 lb in). 9. Install the grille. 10. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 11. Leak test the fittings of the component using the J 39400-A. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > A/C - Control Knob Replacement Availability Control Assembly: Technical Service Bulletins A/C - Control Knob Replacement Availability Bulletin No.: 04-01-37-001 Date: January 06, 2004 INFORMATION Subject: HVAC Control Knob Replacement Models: 2000-2004 All Passenger Cars and Light Duty Trucks 2003-04 HUMMER H2 HVAC Control Knob Availability Important: If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. The various knobs used on the HVAC controls of most GM vehicles are available for purchase separately from the HVAC head units. If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. Please use only the labor operation code listed below when replacing an HVAC control knob. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Recalls: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: Recalls Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Recalls: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 11797 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Recalls: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 11798 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: Customer Interest A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set > Page 11804 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign HVAC Blower Not Functional Runs Continuously Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign HVAC Blower Not Functional Runs Continuously > Page 11810 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign HVAC Blower Not Functional Runs Continuously > Page 11811 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 06-01-38-003 > Apr > 06 > A/C Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 06-01-38-003 > Apr > 06 > A/C Ticking Noise From Instrument Panel/DTC's Set > Page 11816 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 06-01-38-003 > Apr > 06 > A/C Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 06-01-38-003 > Apr > 06 > A/C Ticking Noise From Instrument Panel/DTC's Set > Page 11822 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 11828 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 11829 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Page 11830 Control Module HVAC: Locations HVAC Control Module Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Page 11831 Radio (With RPO Code UB7,Y91 Shown, Others Similar) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > HVAC System - Manual Control Module HVAC: Diagrams HVAC System - Manual HVAC Control Module - C1 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > HVAC System - Manual > Page 11834 HVAC Control Module - C1 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > HVAC System - Manual > Page 11835 HVAC Control Module - C2 Part 1 HVAC Control Module - C2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > HVAC System - Manual > Page 11836 Control Module HVAC: Diagrams HVAC System - Automatic HVAC Control Module - C1 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > HVAC System - Manual > Page 11837 HVAC Control Module - C1 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > HVAC System - Manual > Page 11838 HVAC Control Module - C2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > HVAC System - Manual > Page 11839 HVAC Control Module - C2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation > HVAC System - Manual Control Module HVAC: Description and Operation HVAC System - Manual HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the above features. The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module used for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the above features. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation > HVAC System - Manual > Page 11842 Control Module HVAC: Description and Operation HVAC System - Automatic HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the above features. HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the above features. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic Control Module HVAC: Service and Repair HVAC System - Automatic Blower Motor Control Processor Replacement BLOWER MOTOR CONTROL PROCESSOR REPLACEMENT REMOVAL PROCEDURE 1. If equipped, remove the sound insulator panel. 2. Disconnect the electrical connector at the blower motor. 3. Disconnect the electrical connector (4) from the blower motor control processor (2). 4. Remove the blower motor control processor retaining screws (3) from the HVAC module (1). 5. Remove the blower motor control processor (2) from the HVAC module (1). INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 11845 1. Install the blower motor control processor (2) to the HVAC module (1). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the blower motor control processor retaining screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector (4) to the blower motor control processor (2). 4. Connect the electrical connector at the blower motor. 5. If equipped, install the sound insulator panel. HVAC Control Module Replacement HVAC CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 11846 1. Remove the instrument panel accessory trim plate. 2. Remove the screws from the HVAC control module. 3. Depress the control assembly retaining tabs and remove the HVAC control module from the instrument panel. 4. Disconnect the electrical connectors from the HVAC control module. INSTALLATION PROCEDURE IMPORTANT: The Key should be in the off position when connecting the electrical connectors to ensure proper calibration. 1. Connect the electrical connectors to the HVAC control module. 2. Install the HVAC control module into the instrument panel, ensuring that the HVAC control module retaining tabs lock into place. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws from the HVAC control module. Tighten Tighten the screws to 1.9 N.m (17 lb in). 4. Install the instrument panel accessory trim plate IMPORTANT: Do not adjust any controls on the HVAC control module while the HVAC control module is calibrating. If interrupted improper HVAC performance will result. 5. Start the vehicle and let run for one minute. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 11847 Control Module HVAC: Service and Repair HVAC System - Manual HVAC CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument cluster trim plate bezel. 2. Remove the instrument panel storage tray. 3. Remove the accessory switch assembly from the instrument panel. 4. Remove the screws from the HVAC control assembly. 5. Remove the HVAC control assembly, with the following procedure: 5.1. Release the retaining tabs. 5.2. Pull the control head out of the instrument panel carrier. 6. Disconnect the electrical connectors from the HVAC control assembly. INSTALLATION PROCEDURE IMPORTANT: The Key should be in the off position when connecting the electrical connectors to ensure proper calibration. 1. Connect the electrical connectors to the HVAC control assembly. 2. Install the HVAC control assembly. 3. Install the accessory switch assembly to the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws from the HVAC control assembly. Tighten Tighten the screws to 1.9 N.m (17 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 11848 5. Install the instrument panel storage tray. 6. Install the instrument cluster trim plate bezel. IMPORTANT: Do not adjust any controls on the HVAC control module while the HVAC control module is calibrating. If interrupted improper HVAC performance will result. 7. Start the vehicle and let run for one minute. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > O-Ring Replacement A/C Coupler O-ring: Service and Repair O-Ring Replacement O-RING REPLACEMENT REMOVAL PROCEDURE 1. Disassemble the A/C refrigerant components. - For compression style fittings use a back up wrench on the fitting (2) and loosen the fitting nut (1). - For banjo style fittings remove the bolt retaining the banjo type fitting. 2. Remove the O-ring seal from the A/C refrigerant component. 3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure. 4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. IMPORTANT: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 5. Cap or tape the A/C refrigerant components. 6. Discard the O-ring seal. INSTALLATION PROCEDURE 1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components. IMPORTANT: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system. 4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. IMPORTANT: DO NOT reuse O-ring seals. 5. Carefully slide the new O-ring seal onto the A/C refrigerant component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > O-Ring Replacement > Page 11854 6. The O-ring seal must be fully seated. 7. Assemble the A/C components. Refer to the appropriate repair procedure. For compression style fittings use a back up wrench on the fitting (2) and tighten the fitting nut (1) to specification. - For banjo style fittings install the bolt retaining the banjo type fitting and tighten to specification. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > O-Ring Replacement > Page 11855 A/C Coupler O-ring: Service and Repair Sealing Washer Replacement SEALING WASHER REPLACEMENT REMOVAL PROCEDURE 1. Remove the seal washer from the A/C refrigerant component. IMPORTANT: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 2. Inspect the seal washer for signs of damage to help determine the root cause of the failure. 3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. IMPORTANT: DO NOT reuse sealing washer. 4. Discard the sealing washer. INSTALLATION PROCEDURE IMPORTANT: Flat washer type seals do not require lubrication. 1. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components. 4. Carefully install the new seal washer onto the A/C refrigerant component. The washer must completely bottom against the surface of the fitting. IMPORTANT: After tightening the A/C components, there should be a slight sealing washer gap of approximately 1.2 mm (3/64 in) between the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > O-Ring Replacement > Page 11856 A/C line and the A/C component. 5. Assemble the remaining A/C refrigerant components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations Discharge Air Temperature Sensor / Switch: Locations Air Temperature Sensors - Upper Left And Right Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations > Page 11860 Air Temperature Sensors - Lower Left Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations > Page 11861 Air Temperature Sensors - Lower Right Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper Left Air Temperature Sensor - Upper Left Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper Left > Page 11864 Air Temperature Sensor - Upper Right Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper Left > Page 11865 Air Temperature Sensor - Lower Left Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper Left > Page 11866 Air Temperature Sensor - Lower Right Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Diagrams > Page 11867 Discharge Air Temperature Sensor / Switch: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2-wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: Ambient Air Temperature Sensor - Inside Air Temperature Sensor Assembly - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Air Temperature Sensor A signal and a low-reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0.5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated under the above conditions. The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper Right Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Upper Right AIR TEMPERATURE SENSOR REPLACEMENT - UPPER RIGHT REMOVAL PROCEDURE 1. Remove the I/P upper trim panel. 2. Disconnect the electrical connector (1) from the upper right air temperature sensor (2). 3. Remove the upper right air temperature sensor (1) from the air distributor duct (3). INSTALLATION PROCEDURE 1. Install the upper right air temperature sensor (1) to the air distributor duct (3). 2. Connect the electrical connector (1) from the upper right air temperature sensor (2). 3. Install the I/P upper trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper Right > Page 11870 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Upper Left AIR TEMPERATURE SENSOR REPLACEMENT - UPPER LEFT REMOVAL PROCEDURE 1. Remove the upper left air temperature sensor (2) from the air distributor duct (1). 2. Disconnect the electrical connector (3) from the upper left air temperature sensor (2). INSTALLATION PROCEDURE 1. Install the upper left air temperature sensor (2) to the air distributor duct (1). 2. Connect the electrical connector (3) to the upper left air temperature sensor (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper Right > Page 11871 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower Left AIR TEMPERATURE SENSOR REPLACEMENT - LOWER LEFT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the lower left air temperature sensor (1). 2. Remove the lower left air temperature sensor (1) from the HVAC module (2). INSTALLATION PROCEDURE 1. Install the lower left air temperature sensor (1) to the HVAC module (2). 2. Connect the electrical connector to the lower left air temperature sensor (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper Right > Page 11872 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower Right AIR TEMPERATURE SENSOR REPLACEMENT - LOWER RIGHT REMOVAL PROCEDURE 1. Remove the I/P lower closeout panel. 2. Remove the right floor duct. 3. Remove the center console. 4. Disconnect the electrical connector from the lower right air temperature sensor (1). 5. Remove the lower right air temperature sensor (1). INSTALLATION PROCEDURE 1. Install the lower right air temperature sensor (1). 2. Connect the electrical connector to the lower right air temperature sensor (1). 3. Install the center console. 4. Install the right floor duct. 5. Install the I/P lower closeout panel Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: Customer Interest A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 11881 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 11882 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 11888 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 11889 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement (Delphi) Evaporator Core: Service and Repair Evaporator Core Replacement (Delphi) Air Conditioning Evaporator Core Replacement (Delphi) Removal Procedure 1. Remove the HVAC module. 2. If equipped remove the heat stakes (1) from the HVAC module (2) with a screw driver and a hammer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement (Delphi) > Page 11892 3. If equipped remove the screws from the HVAC module assembly. 4. Remove the evaporator cowl gasket from the evaporator. 5. Separate the upper HVAC module assembly (2) from the lower HVAC module assembly (1). 6. Remove the evaporator core (1) from the upper HVAC module assembly. Installation Procedure Important: If replacing the evaporator core, add the refrigerant oil the evaporator core. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement (Delphi) > Page 11893 1. Install the evaporator core (1) to the HVAC module assembly (2). 2. Install the upper HVAC module assembly (2) from the lower HVAC module assembly. 3. Install the evaporator cowl gasket to the evaporator. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for the application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 4. Install the screws to the HVAC module assembly. Tighten Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement (Delphi) > Page 11894 Tighten the screws to 2 Nm (18 lb in). 5. Install the HVAC module assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement (Delphi) > Page 11895 Evaporator Core: Service and Repair Evaporator Core Replacement (Visteon) Air Conditioning Evaporator Core Replacement (Visteon) Removal Procedure 1. Remove the HVAC module. 2. Disconnect the electrical connector from the recirculation actuator. 3. Remove the screws from the evaporator cover (1). 4. Remove the evaporator cover (1) from the HVAC module assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement (Delphi) > Page 11896 5. Remove the evaporator cowl gasket (1) from the evaporator (2). 6. Remove the evaporator core (1) from the HVAC module assembly (2). Installation Procedure Important: If replacing the condenser, add the refrigerant oil to the evaporator core. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement (Delphi) > Page 11897 1. Install the evaporator core (1) to the HVAC module assembly (2). 2. Install the evaporator cowl gasket (1) to the evaporator (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement (Delphi) > Page 11898 3. Install the evaporator cover (1) to the HVAC module assembly (2). Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 4. Install the screws to the evaporator cover (1). Tighten Tighten the screws to 2 Nm (18 lb in). 5. Connect the electrical connector to the recirculation actuator (1). 6. Install the HVAC module assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair Expansion Block/Orifice Tube: Service and Repair EXPANSION (ORIFICE) TUBE REPLACEMENT TOOLS REQUIRED - J 26549-E Orifice Tube Remover - J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . 2. Loosen the nut from the evaporator tube fitting. 3. Use the J 26549-E in order to remove the orifice tube (1) from the evaporator tube (2). 4. Cap or plug the open line. INSTALLATION PROCEDURE 1. Uncap or unplug the evaporator tube. 2. Lubricate the new O-ring using new 525 viscosity refrigerant oil. 3. Install the new O-ring seal. 4. Install the orifice tube (1) to the evaporator tube (2). 4.1. Coat the O-ring seal with 525 viscosity refrigerant oil. 4.2. Insert the short screen end of the new orifice (1) into the evaporator tube. NOTE: Refer to Fastener Notice in Service Precautions. 5. Connect the evaporator tube at the fitting. Tighten Tighten the fitting to 25 N.m (18 lb ft). 6. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 7. Leak test the fittings of the repaired component using J 39400-A. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 11906 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 11907 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Replacement Heater Core: Service and Repair Heater Core Replacement HEATER CORE REPLACEMENT (HEAT ONLY) REMOVAL PROCEDURE 1. Remove the heater/vent module. See: 2. Remove the heater core cover screws. 3. Remove the heater core cover. 4. Remove the heater core. INSTALLATION PROCEDURE 1. Install the heater core. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 11910 2. Install the heater core cover. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install heater core cover screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 4. Install the heater/vent module. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 11911 Heater Core: Service and Repair Heater Core Replacement - Delphi HEATER CORE REPLACEMENT (DELPHI) REMOVAL PROCEDURE 1. Remove the HVAC module assembly. See: Housing Assembly HVAC/Service and Repair/HVAC Module Assembly Replacement 2. Remove the screws from the heater core cover. 3. Remove the heater core cover (1) from the HVAC module assembly (2). 4. Remove the heater core cowl gasket (1) from the heater core (2). 5. Remove the heater core (2) from the HVAC module assembly (3). INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 11912 1. Install the heater core (2) to the HVAC module assembly (3). 2. Install the heater core cowl gasket (1) to the heater core (2). 3. Install the heater core cover (1) to the HVAC module assembly (2). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the heater core cover (1). Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the HVAC module assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 11913 Heater Core: Service and Repair Heater Core Replacement - Visteon HEATER CORE REPLACEMENT (VISTEON) REMOVAL PROCEDURE 1. Remove the HVAC module assembly. See: Housing Assembly HVAC/Service and Repair 2. Remove the screws from the heater core cover. 3. Remove the heater core cover (1) from the HVAC module assembly (2). 4. Remove the heater core cowl gasket (1) from the heater core (2). 5. Remove the heater core (1) from the HVAC module assembly (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 11914 INSTALLATION PROCEDURE 1. Install the heater core (1) to the HVAC module assembly (2). 2. Install the heater core cowl gasket (1) to the HVAC module assembly (2). 3. Install the heater core cover (1) to the HVAC module assembly (2). NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the heater core cover (1). Tighten Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Replacement > Page 11915 Tighten the screws to 2 N.m (18 lb in). 5. Install the HVAC module assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet (With RPO Code HP2 Front) Heater Hose: Service and Repair Heater Hose Replacement - Inlet (With RPO Code HP2 Front) HEATER HOSE REPLACEMENT - INLET (W/ HP2 FRONT) REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Loosen the air cleaner outlet duct clamps at the following locations: - Throttle body - Mass airflow/intake air temperature (MAF/IAT) sensor 3. Remove the radiator inlet hose clip from the outlet duct. 4. Remove the air cleaner outlet duct. 5. Reposition the inlet heater hose clamp from the engine. 6. Remove the inlet heater hose from the engine. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet (With RPO Code HP2 Front) > Page 11920 7. Reposition the inlet heater hose clamp (4) from the auxiliary water pump (1). 8. Remove the inlet heater hose (6) from the auxiliary water pump (1). INSTALLATION PROCEDURE 1. Install the inlet heater hose (6) to the auxiliary water pump (1). 2. Position the inlet heater hose clamp (4) to the auxiliary water pump (1). 3. Install the inlet heater hose to the engine. 4. Position the inlet heater hose clamp to the engine. IMPORTANT: Align the arrow at the throttle body end of the duct with the throttle body attaching stud. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet (With RPO Code HP2 Front) > Page 11921 5. Install the air cleaner outlet duct. 6. Install the radiator inlet hose clip to the outlet duct. NOTE: Refer to Fastener Notice in Service Precautions. 7. Tighten the air cleaner outlet duct clamps at the following locations: - Throttle body - MAF/IAT sensor Tighten Tighten the screws to 7 N.m (62 lb in). 8. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet (With RPO Code HP2 Front) > Page 11922 Heater Hose: Service and Repair Heater Hose Replacement - Inlet (With RPO Code HP2 Rear) HEATER HOSE REPLACEMENT - INLET (W/ HP2 REAR) TOOLS REQUIRED J 43181 Quick Connect Connector Removal Tool REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. Using the J 43181 disconnect the heater hose from the heater core inlet. 2.1. Install the J 43181 to the heater core pipe. 2.2. Close the tool around the heater core pipe. 2.3. Firmly pull the tool into the quick connect end of the heater hose. 2.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core. 3. Reposition the inlet heater hose clamp (2) from the auxiliary water pump (1). 4. Remove the inlet heater hose (3) from the auxiliary water pump (1). INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet (With RPO Code HP2 Front) > Page 11923 1. Install the inlet heater hose (3) to the auxiliary water pump (1). 2. Position the inlet heater hose clamp (2) to the auxiliary water pump (1). 3. Connect the inlet heater hose to the heater core. 4. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 5. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough Hose/Line HVAC: Customer Interest A/C - Doesn't Blow Cold Enough Bulletin No.: 02-01-38-007C Date: July 27, 2004 TECHNICAL Subject: Poor A/C Performance - A/C Will Not Blow Cold Enough (Perform A/C System Checks, Replace Accumulator if Necessary) Models: 2002-2004 Chevrolet Silverado 2002-2004 GMC Sierra with 6.6L Diesel Engine (VINs 1, 2 - RPOs LB7, LLY) and Denso A/C Compressor Supercede: This bulletin is being revised to add part numbers for the hose, bracket and insulator to the Parts Information. Please discard Corporate Bulletin Number 02-01-38-007B (Section 01 - HVAC). Condition Some customers may comment on less than desirable A/C performance, especially when the ambient temperature is above 32°C (90°F). Correction Perform the following A/C system checks and replace the accumulator with P/N 89018601, if necessary. This new accumulator requires the accumulator bracket, the accumulator insulator and the A/C suction hose to be replaced also. ^ Check for A/C system leaks. ^ Check the A/C system for proper refrigerant charge. This requires recovering the refrigerant to determine charge in system. Refer to Refrigerant Recovery and Recharging in the HVAC sub-section of the Service Manual. ^ If no leaks were found and the A/C system is charged to specification, replace the accumulator using the procedure listed below. If normal diagnostics do not lead to a correction, then perform the following A/C system checks. 1. Re-calibrate the actuators. 2. Inspect the lower A/C condenser deflector for proper installation. The deflector should be positioned at the lower part of the condenser and extend forward into the top of the front bumper and below the two fresh air intake holes. 3. Check the engine cooling fan clutch for proper operation. 4. If the vehicle is equipped with a front license plate, inspect for proper installation. If the license plate bracket is installed upside down, it will block part of the two fresh air intake holes in the bumper. When the license plate bracket is installed correctly, the writing on the back of the bracket will be upside down. Inspect for material between the radiator and condenser. Remove the top plate to confirm that there is no restriction. A radiator front filled with material will decrease condenser performance. 5. Some improvements have been found by lowering the A/C charge from 0.82 kg (1.8 lbs) to 0.73 kg (1.6 lbs). 6. Check the low pressure cycling switch for proper operation. The low pressure switch opens at 172-234 kPa (25-34 psi) which stops compressor operation and closes when the low side pressure reaches 276-310 kPa (40-45 psi). This enables the compressor to turn back on. Important: Compressor clutch engagement cannot be used to determine the status of the low pressure switch. The low pressure switch is one of several inputs to the HVAC control module for A/C request authorization. A/C request is one of several inputs to the powertrain control module (PCM) that control A/C compressor clutch engagement. Using a scan tool to monitor low pressure switch status while monitoring the low side pressure with the ACR 2000 at the service port and watch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough > Page 11932 the pressure at which the switch opens/closes is imperative to successfully diagnosing the switch. 7. If the A/C performance has not improved after performing the above steps, replace the accumulator with P/N 89018601, using the procedure listed below. This new accumulator also requires the accumulator bracket, accumulator insulator and A/C suction hose to be replaced. Accumulator Replacement 1. Remove the suction hose mounting bolt from the A/C compressor. 2. Remove the suction hose from the compressor. 3. Remove the suction hose nut from the accumulator. 4. Remove the suction hose from the accumulator. 5. Remove the evaporator tube nut from the evaporator. 6. Remove the evaporator tube from the evaporator. 7. Disconnect the electrical connector from the A/C low pressure switch. 8. Remove the nut from the evaporator fitting. 9. Remove the accumulator bracket nut from the retaining stud. 10. Remove the accumulator. 11. Remove the retaining bracket bolt. This bolt must be reused for the new bracket. 12. Remove the insulator. One half of the insulator must be reused. 13. Install the new insulator and one half of the old insulator onto the new accumulator. 14. Install the new retaining bracket and bolt to the accumulator. Do not tighten at this time. 15. Add the PAG oil directly into the new accumulator that was removed during the recovery process plus an additional 90 ml (3 oz). 16. Install the new accumulator. 17. Install the accumulator bracket nut. Tighten Tighten the nut to 9 N.m (80 lb in). 18. Tighten the retaining bracket bolt. Tighten Tighten the nut to 10 N.m (89 lb in). 19. Install the nut to the evaporator fitting. Tighten Tighten the nut to 16 N.m (12 lb ft). 20. Install the evaporator tube to the evaporator. 21. Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N.m (12 lb ft). 22. Install the new suction hose to the accumulator. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough > Page 11933 23. Install the suction hose nut to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft). 24. Connect the electrical connector to the A/C low pressure switch. 25. Install the new suction hose to the compressor. 26. Install the suction hose mounting bolt to the A/C compressor. Tighten Tighten the bolt to 16 N.m (12 lb ft). Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough Hose/Line HVAC: All Technical Service Bulletins A/C - Doesn't Blow Cold Enough Bulletin No.: 02-01-38-007C Date: July 27, 2004 TECHNICAL Subject: Poor A/C Performance - A/C Will Not Blow Cold Enough (Perform A/C System Checks, Replace Accumulator if Necessary) Models: 2002-2004 Chevrolet Silverado 2002-2004 GMC Sierra with 6.6L Diesel Engine (VINs 1, 2 - RPOs LB7, LLY) and Denso A/C Compressor Supercede: This bulletin is being revised to add part numbers for the hose, bracket and insulator to the Parts Information. Please discard Corporate Bulletin Number 02-01-38-007B (Section 01 - HVAC). Condition Some customers may comment on less than desirable A/C performance, especially when the ambient temperature is above 32°C (90°F). Correction Perform the following A/C system checks and replace the accumulator with P/N 89018601, if necessary. This new accumulator requires the accumulator bracket, the accumulator insulator and the A/C suction hose to be replaced also. ^ Check for A/C system leaks. ^ Check the A/C system for proper refrigerant charge. This requires recovering the refrigerant to determine charge in system. Refer to Refrigerant Recovery and Recharging in the HVAC sub-section of the Service Manual. ^ If no leaks were found and the A/C system is charged to specification, replace the accumulator using the procedure listed below. If normal diagnostics do not lead to a correction, then perform the following A/C system checks. 1. Re-calibrate the actuators. 2. Inspect the lower A/C condenser deflector for proper installation. The deflector should be positioned at the lower part of the condenser and extend forward into the top of the front bumper and below the two fresh air intake holes. 3. Check the engine cooling fan clutch for proper operation. 4. If the vehicle is equipped with a front license plate, inspect for proper installation. If the license plate bracket is installed upside down, it will block part of the two fresh air intake holes in the bumper. When the license plate bracket is installed correctly, the writing on the back of the bracket will be upside down. Inspect for material between the radiator and condenser. Remove the top plate to confirm that there is no restriction. A radiator front filled with material will decrease condenser performance. 5. Some improvements have been found by lowering the A/C charge from 0.82 kg (1.8 lbs) to 0.73 kg (1.6 lbs). 6. Check the low pressure cycling switch for proper operation. The low pressure switch opens at 172-234 kPa (25-34 psi) which stops compressor operation and closes when the low side pressure reaches 276-310 kPa (40-45 psi). This enables the compressor to turn back on. Important: Compressor clutch engagement cannot be used to determine the status of the low pressure switch. The low pressure switch is one of several inputs to the HVAC control module for A/C request authorization. A/C request is one of several inputs to the powertrain control module (PCM) that control A/C compressor clutch engagement. Using a scan tool to monitor low pressure switch status while monitoring the low side pressure with the ACR 2000 at the service port and watch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough > Page 11939 the pressure at which the switch opens/closes is imperative to successfully diagnosing the switch. 7. If the A/C performance has not improved after performing the above steps, replace the accumulator with P/N 89018601, using the procedure listed below. This new accumulator also requires the accumulator bracket, accumulator insulator and A/C suction hose to be replaced. Accumulator Replacement 1. Remove the suction hose mounting bolt from the A/C compressor. 2. Remove the suction hose from the compressor. 3. Remove the suction hose nut from the accumulator. 4. Remove the suction hose from the accumulator. 5. Remove the evaporator tube nut from the evaporator. 6. Remove the evaporator tube from the evaporator. 7. Disconnect the electrical connector from the A/C low pressure switch. 8. Remove the nut from the evaporator fitting. 9. Remove the accumulator bracket nut from the retaining stud. 10. Remove the accumulator. 11. Remove the retaining bracket bolt. This bolt must be reused for the new bracket. 12. Remove the insulator. One half of the insulator must be reused. 13. Install the new insulator and one half of the old insulator onto the new accumulator. 14. Install the new retaining bracket and bolt to the accumulator. Do not tighten at this time. 15. Add the PAG oil directly into the new accumulator that was removed during the recovery process plus an additional 90 ml (3 oz). 16. Install the new accumulator. 17. Install the accumulator bracket nut. Tighten Tighten the nut to 9 N.m (80 lb in). 18. Tighten the retaining bracket bolt. Tighten Tighten the nut to 10 N.m (89 lb in). 19. Install the nut to the evaporator fitting. Tighten Tighten the nut to 16 N.m (12 lb ft). 20. Install the evaporator tube to the evaporator. 21. Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N.m (12 lb ft). 22. Install the new suction hose to the accumulator. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough > Page 11940 23. Install the suction hose nut to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft). 24. Connect the electrical connector to the A/C low pressure switch. 25. Install the new suction hose to the compressor. 26. Install the suction hose mounting bolt to the A/C compressor. Tighten Tighten the bolt to 16 N.m (12 lb ft). Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement (Without RPO Code HP2) Hose/Line HVAC: Service and Repair Evaporator Tube Replacement (Without RPO Code HP2) EVAPORATOR TUBE REPLACEMENT (W/O HP2) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Remove the evaporator tube nut from the evaporator. 3. Remove the evaporator tube from the evaporator. 4. Remove the right park/turn signal lamp. 5. Remove the grille from the vehicle. 6. Remove the evaporator tube nut from the condenser. 7. Remove the evaporator tube from the condenser. 8. Remove the evaporator tube from the vehicle. 9. Discard all of the used sealing washers. Cap all of the open connections. INSTALLATION PROCEDURE 1. Install the evaporator tube to the condenser using new sealing washers. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement (Without RPO Code HP2) > Page 11943 2. Install the evaporator tube nut to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft). 3. Install the grille to the vehicle. 4. Install the right park/turn signal lamp. 5. Install the evaporator tube to the evaporator. 6. Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N.m (12 lb ft). 7. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 8. Leak test the fittings of the components using the J 39400-A. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement (Without RPO Code HP2) > Page 11944 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement (With RPO Code HP2) EVAPORATOR TUBE REPLACEMENT (W/ HP2) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Remove the evaporator tube nut from the evaporator. 3. Remove the evaporator tube from the evaporator. 4. Loosen the nut from the evaporator tube fitting. 5. Remove the rear evaporator tube (3) from the vehicle. 6. Remove the air cleaner assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement (Without RPO Code HP2) > Page 11945 7. Remove the push pin from the right side radiator air baffle. 8. Remove the bolts (2) from the starter/generator control module (SGCM) coolant pump (1). 9. Reposition the SGCM coolant pump. 10. Remove the right park/turn signal lamp. 11. Remove the grille from the vehicle. 12. Remove the evaporator tube nut from the condenser. 13. Remove the evaporator tube from the condenser. 14. Remove the front evaporator tube from the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement (Without RPO Code HP2) > Page 11946 15. Discard all of the used sealing washers. Cap all of the open connections. INSTALLATION PROCEDURE 1. Install the front evaporator tube to the vehicle. 2. Uncap all of the open connections 3. Install the evaporator tube to the condenser using new sealing washers. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the evaporator tube nut to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft). 5. Install the grille to the vehicle. 6. Install the right park/turn signal lamp. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement (Without RPO Code HP2) > Page 11947 7. Position the SGCM coolant pump (1) to the radiator core support (3). 8. Install the bolts (2) to the SGCM coolant pump (1). Tighten Tighten the nut to 16 N.m (12 lb ft). 9. Install the push pin to the right side radiator air baffle. 10. Install the air cleaner assembly. 11. Install the rear evaporator tube (3) to the vehicle. 12. Connect the nut to the evaporator tube fitting. Tighten Tighten the nut to 9 N.m (80 lb in). 13. Install the evaporator tube to the evaporator. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Evaporator Tube Replacement (Without RPO Code HP2) > Page 11948 14. Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N.m (12 lb ft). 15. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 16. Leak test the fittings of the components using the J 39400-A. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > A/C - HVAC Module External Seal Kit Availability Housing Assembly HVAC: Technical Service Bulletins A/C - HVAC Module External Seal Kit Availability Bulletin No.: 04-01-38-018 Date: November 30, 2004 INFORMATION Subject: HVAC Module External Seal Kit Now Available For Service Use Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL with Air Conditioning (RPOS CJ2 and CJ3) The purpose of this bulletin is to inform dealer technicians that the external Heating, Ventilation and Air Conditioning (HVAC) module seals are now available for service use. The individual external module seals are not available separately. They are only available as part of the seal kit. The seal kit, P/N 89024877, consists of the following seven parts: ^ A/C Evaporator Case Drain Tube Seal ^ A/C Evaporator Seal ^ A/C Evaporator Tube Seal ^ Air Distribution Case Seal ^ Air Inlet Valve Seal ^ Heater and A/C Evaporator and Blower Module Seal ^ Heater Core Tube Seal Parts Information Parts are currently available from GMSPO. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater/Vent Module Replacement Housing Assembly HVAC: Service and Repair Heater/Vent Module Replacement HEATER/VENT MODULE REPLACEMENT REMOVAL PROCEDURE 1. Drain the engine coolant. 2. If equipped remove the auxiliary battery. 3. Reposition the inlet heater hose clamp from the heater core. 4. Remove the inlet heater hose from the heater core. 5. Reposition the outlet heater hose clamp from the heater core. 6. Remove the outlet heater hose from the heater core. 7. Remove the I/P carrier. 8. Remove the heater/vent module drain hose. 9. Disconnect the electrical harnesses and the ground connections. 10. Remove the heater/vent module mounting nuts and the screws. 11. Remove the heater/vent module assembly from the vehicle. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater/Vent Module Replacement > Page 11955 1. Install the heater/vent module assembly to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the heater/vent module mounting nuts. Tighten Tighten the nuts to 9 N.m (80 lb in). 3. Install the heater/vent module mounting screws. Tighten Tighten the screws to 4 N.m (35 lb in). 4. Connect the electrical harnesses and the ground connections. 5. Install the heater/vent module drain hose. 6. Install the I/P carrier. 7. Install the outlet heater hose to the heater core. 8. Reposition the outlet heater hose clamp to the heater core. 9. Install the inlet heater hose to the heater core. 10. Reposition the inlet heater hose clamp to the heater core. 11. Fill the cooling system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater/Vent Module Replacement > Page 11956 Housing Assembly HVAC: Service and Repair HVAC Module Assembly Replacement HVAC MODULE ASSEMBLY REPLACEMENT TOOLS REQUIRED J 43181 Quick Connect Connector Removal Tool REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. 2. If equipped remove the auxiliary battery. 3. Using the J 43181 disconnect the inlet heater hose from the heater core. 3.1. Install the J 43181 to the heater core pipe. 3.2. Close the tool around the heater core pipe. 3.3. Firmly pull the tool into the quick connect end of the heater hose. 3.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the inlet hose from the heater core. 4. Using the J 43181 disconnect the surge tank outlet hose from the heater core. 4.1. Install the J 43181 to the heater core pipe. 4.2. Close the tool around the heater core pipe. 4.3. Firmly pull the tool into the quick connect end of the heater hose. 4.4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the surge tank outlet hose from the heater core. 5. Remove the accumulator. 6. Remove the instrument panel carrier. 7. Remove the HVAC module drain hose. 8. Disconnect the electrical harnesses and the ground connections from the HVAC module. 9. Remove the nuts (4) from the HVAC module (2). 10. Remove the bolts (3) from the HVAC module (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater/Vent Module Replacement > Page 11957 11. Remove the HVAC module (2) from the vehicle (1). INSTALLATION PROCEDURE 1. If replacing the HVAC module, transfer the components from the old HVAC module as necessary. 2. Install the HVAC module (2) to the vehicle (1). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the nuts (4) to the HVAC module (2). Tighten Tighten the nuts to 9 N.m (80 lb in). 4. Install the bolts (4) to the HVAC module (2). Tighten Tighten the bolts to 4 N.m (35 lb in). 5. Connect the electrical harnesses and the ground connections. 6. Install the HVAC module drain hose. 7. Install the instrument panel carrier. 8. Install the accumulator. 9. Install the surge tank outlet hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 10. Install the inlet heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 11. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2)Draining and Filling Cooling System (without HP2) in Cooling System. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 11962 Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 11963 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Charge .............................................................................................................................. ........................................................... 0.7 kg (1.6 lbs) Refrigerant Charge with Front and Rear A/C ................................................................................................................................................ 1.13 kg (2.5 lb) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 11966 Refrigerant: Fluid Type Specifications Air Conditioning Refrigerant ....................................................................................................................... R134a P/N 12356150 U.S. (10953485 Canada) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 11967 Refrigerant: Service and Repair REFRIGERANT RECOVERY AND RECHARGING TOOLS REQUIRED - J 43600 ACR 2000 Air Conditioning Service Center - J 45037 A/C Oil Injector CAUTION: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. - For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. NOTE: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. - To avoid system damage use only R-134a dedicated tools when servicing the A/C system. - Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. - R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the correct amount. A/C REFRIGERANT SYSTEM OIL CHARGE REPLENISHING If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037 . For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Filter: > 03-01-38-019A > Sep > 04 > A/C - Underhood Rattle Noise on Hard Acceleration Refrigerant Filter: Customer Interest A/C - Underhood Rattle Noise on Hard Acceleration File In Section: 01 - HVAC Bulletin No.: 03-01-38~019A Date: September, 2004 TECHNICAL Subject: Underhood Rattle Noise Heard On Acceleration (Check A/C System Performance and Compressor Operation) Models: 2003-2004 Cadillac CTS 2002-2004 Cadillac Escalade, Escalade EXT 2003-2004 Cadillac Escalade ESV 2002-2004 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2002-2004 GMC Denali, Denali XL, Savana, Sierra, Yukon, Yukon XL 2002-2004 Commercial Upfitter Chassis Vehicles with Air Conditioning (A/C) This bulletin is being revised to update the service procedure and parts information. Please discard Corporate Bulletin Number 03-01-38-019 (Section 01 - HVAC). Condition Some customers may comment about an underhood rattle noise heard on acceleration or a sudden loss of A/C system performance. Cause This condition may be caused by liquid slugging of the A/C compressor. This condition may cause an internal failure in the A/C compressor. The serpentine belt tensioner and serpentine belt may also be damaged. Correction Technicians are to check the A/C system performance and compressor operation using the following repair procedure: 1. Open the hood and inspect the A/C compressor for damage and to see if the compressor is seized. Verify that the serpentine belt is not damaged or missing. If the A/C compressor is seized, proceed to Step 5. 2. Perform the A/C System Performance test. Refer to the Heating, Ventilation and Air Conditioning (HVAC) section of SI. Correct any performance concerns or refrigerant leaks that are found. 3. Inspect the vehicle for other possible sources of A/C compressor noise or performance concerns. Refer to Corporate Bulletin Number 01-01-38-013 for more information. 4. After all other possible sources of A/C compressor noise or performance concerns have been eliminated, only then should the A/C compressor be replaced. 5. Remove the A/C compressor. Refer to the A/C Compressor Replacement procedure in the HVAC section of SI. 6. Inspect the transmission cooler lines for damage due to contact from the serpentine belt. Replace the transmission cooler lines if necessary. 7. Install an inline A/C system filter. Refer to Corporate Bulletin Number 01-01-38-006C for more information about A/C system flushing and filter installation procedures. An A/C system flush is not to be done unless prior authorization is given by the GM Area Service Manager (in Canada, the District Service Manager). 8. Install an A/C Suction Screen. Refer to Corporate Bulletin Number 01-01-39-003A for more information about A/C suction screen repair recommendations and procedures. 9. Install a new A/C compressor. Refer to the Compressor Replacement procedure in the HVAC section of SI. 10. Install a new orifice tube for the front A/C system. Refer to the Expansion (Orifice) Tube Replacement procedure in SI. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > Customer Interest for Refrigerant Filter: > 03-01-38-019A > Sep > 04 > A/C - Underhood Rattle Noise on Hard Acceleration > Page 11976 11. If the vehicle is a 2003 model year Chevrolet Express or GMC Savana van, the vehicle may require a new accumulator. Refer to Corporate Bulletin Number 03-01-38-016 for more information. This bulletin refers to an updated design accumulator that may improve the performance of the A/C system. 12. Install a new serpentine belt tensioner and serpentine belt if they have been damaged due to A/C system slugging or an A/C compressor seizure. The serpentine belt tensioner may have broken stop tabs and/or a missing front cap. 13. Verify proper operation of the A/C system. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Filter: > 03-01-38-019A > Sep > 04 > A/C - Underhood Rattle Noise on Hard Acceleration Refrigerant Filter: All Technical Service Bulletins A/C - Underhood Rattle Noise on Hard Acceleration File In Section: 01 - HVAC Bulletin No.: 03-01-38~019A Date: September, 2004 TECHNICAL Subject: Underhood Rattle Noise Heard On Acceleration (Check A/C System Performance and Compressor Operation) Models: 2003-2004 Cadillac CTS 2002-2004 Cadillac Escalade, Escalade EXT 2003-2004 Cadillac Escalade ESV 2002-2004 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2002-2004 GMC Denali, Denali XL, Savana, Sierra, Yukon, Yukon XL 2002-2004 Commercial Upfitter Chassis Vehicles with Air Conditioning (A/C) This bulletin is being revised to update the service procedure and parts information. Please discard Corporate Bulletin Number 03-01-38-019 (Section 01 - HVAC). Condition Some customers may comment about an underhood rattle noise heard on acceleration or a sudden loss of A/C system performance. Cause This condition may be caused by liquid slugging of the A/C compressor. This condition may cause an internal failure in the A/C compressor. The serpentine belt tensioner and serpentine belt may also be damaged. Correction Technicians are to check the A/C system performance and compressor operation using the following repair procedure: 1. Open the hood and inspect the A/C compressor for damage and to see if the compressor is seized. Verify that the serpentine belt is not damaged or missing. If the A/C compressor is seized, proceed to Step 5. 2. Perform the A/C System Performance test. Refer to the Heating, Ventilation and Air Conditioning (HVAC) section of SI. Correct any performance concerns or refrigerant leaks that are found. 3. Inspect the vehicle for other possible sources of A/C compressor noise or performance concerns. Refer to Corporate Bulletin Number 01-01-38-013 for more information. 4. After all other possible sources of A/C compressor noise or performance concerns have been eliminated, only then should the A/C compressor be replaced. 5. Remove the A/C compressor. Refer to the A/C Compressor Replacement procedure in the HVAC section of SI. 6. Inspect the transmission cooler lines for damage due to contact from the serpentine belt. Replace the transmission cooler lines if necessary. 7. Install an inline A/C system filter. Refer to Corporate Bulletin Number 01-01-38-006C for more information about A/C system flushing and filter installation procedures. An A/C system flush is not to be done unless prior authorization is given by the GM Area Service Manager (in Canada, the District Service Manager). 8. Install an A/C Suction Screen. Refer to Corporate Bulletin Number 01-01-39-003A for more information about A/C suction screen repair recommendations and procedures. 9. Install a new A/C compressor. Refer to the Compressor Replacement procedure in the HVAC section of SI. 10. Install a new orifice tube for the front A/C system. Refer to the Expansion (Orifice) Tube Replacement procedure in SI. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Filter: > 03-01-38-019A > Sep > 04 > A/C - Underhood Rattle Noise on Hard Acceleration > Page 11982 11. If the vehicle is a 2003 model year Chevrolet Express or GMC Savana van, the vehicle may require a new accumulator. Refer to Corporate Bulletin Number 03-01-38-016 for more information. This bulletin refers to an updated design accumulator that may improve the performance of the A/C system. 12. Install a new serpentine belt tensioner and serpentine belt if they have been damaged due to A/C system slugging or an A/C compressor seizure. The serpentine belt tensioner may have broken stop tabs and/or a missing front cap. 13. Verify proper operation of the A/C system. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Installation Refrigerant Filter: Service and Repair Installation AIR CONDITIONING (A/C) REFRIGERANT FILTER INSTALLATION TOOLS REQUIRED J 39400-A Halogen Leak Detector IMPORTANT: The A/C Refrigerant filter, ACDelco P/N 15-1696 must be installed to the A/C evaporator tube between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Remove the air cleaner. 2. Measure 50 mm (2 in) from the bend on the evaporator tube (2) near the expansion tube end and mark the location. 3. Measure 50.8 mm (2 in) from the mark on the evaporator tube (2) from the previous step. IMPORTANT: Do not allow metal burrs to enter the evaporator tube (2) during cutting or when removing the burrs. 4. Using a tubing cutter, cut the marked section of the evaporator tube (2). 5. Remove the burrs from the evaporator tube (2). 6. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). IMPORTANT: DO NOT install the O-rings (2) in this step. 7. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves. 8. Install the ferrules (3) with the small end toward the nut (4). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Installation > Page 11985 9. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 10. While holding the evaporator tube in the A/C refrigerant filter (1), tighten the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 11. Remove the nuts (4) from the A/C refrigerant filter (1). 12. Coat the O-rings (2) with 525 viscosity refrigerant oil. 13. Install the O-rings (2) to the evaporator tube halves. 14. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 15. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 16. Leak test the fittings of the component using the J 39400-A. 17. Install the air cleaner. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Installation > Page 11986 Refrigerant Filter: Service and Repair Replacement AIR CONDITIONING (A/C) REFRIGERANT FILTER REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. IMPORTANT: The nuts (4) and the ferrules (3) will remain on the evaporator tube. Do not try to remove. 3. Remove the nuts (4) from the A/C refrigerant filter (1). 4. Remove the A/C refrigerant filter (3) from the evaporator tube (2). INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Installation > Page 11987 1. Coat the O-rings (2) with 525 viscosity refrigerant oil. 2. Install the O-rings (2) to the evaporator tube. 3. Install the A/C refrigerant filter (3) to the evaporator tube (2) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 5. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Installation > Page 11988 6. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 7. Install the air cleaner. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL CAPACITIES ACCUMULATOR REPLACEMENT NOTE: Add 60 ml (2 oz) of PAG oil, plus the equal amount of oil drained from the accumulator. COMPRESSOR REPLACEMENT ......................................................................................................................................................... 60 ml (2.0 oz) NOTE:The Denso replacement compressor is precharged with 237 ml (8.0 oz) of PAG oil. CONDENSER REPLACEMENT ............................................................................................................................................................ 30 ml (1.0 oz) EVAPORATOR REPLACEMENT ......................................................................................................................................................... 90 ml (3.0 oz) NOTE: If more than the specified amount of PAG oil was drained from a component, add the equal amount drained. TOTAL SYSTEM PAG OIL CAPACITY ............................................................................................................................................ 240 ml (8.0 oz) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 11995 Refrigerant Oil: Fluid Type Specifications REFRIGERANT OIL PAG Oil GM P/N 12378526 (Canadian P/N 88900060) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 11996 Refrigerant Oil: Service and Repair A/C REFRIGERANT SYSTEM OIL CHARGE REPLENISHING If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037 . For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations Forward Lamp Harness Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Air Conditioning - Diagnose A/C Low Pressure Switch Low Pressure Sensor / Switch: Technical Service Bulletins Air Conditioning - Diagnose A/C Low Pressure Switch INFORMATION Bulletin No.: 04-01-38-010A Date: January 21, 2010 Subject: Diagnostic Information to Accurately Diagnose A/C Low Pressure Switch Using Kent Moore Special Tool GE-47742 Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2007 Chevrolet Silverado 2000-2006 Chevrolet Suburban, Tahoe 2002-2007 Chevrolet Avalanche 1999-2007 GMC Sierra 2000-2006 GMC Yukon, Yukon XL 2001-2006 GMC Yukon Denali XL 2001-2007 GMC Sierra Denali, Yukon Denali XL 2003-2008 HUMMER H2 with Air Conditioning Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 04-01-38-010 (Section 01 - HVAC). Currently, technicians cannot accurately determine the air conditioning (A/C) low pressure switch open/close pressure point by measuring pressure at the low side service port. This is because the evaporator is between the low side service port and the A/C low pressure switch. Correlating pressures measured at the low side service port to actual pressures at the A/C low pressure switch port is difficult because of the multiple variables that impact pressure drop across the evaporator. Providing a pressure range that would take into account all these variables would result in a pressure range that would be too broad to be useful for diagnostic purposes. Kent Moore special tool GE-47742 will allow technicians to monitor the actual pressures at which the A/C low pressure switch opens and closes under actual operating conditions. Technicians are to use the following steps to install and use Kent Moore special tool GE-47742 to measure A/C low pressure switch opening and closing pressures: 1. Disconnect the wire harness from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Install the A/C low pressure switch, using the threaded port with an O-ring, onto special tool GE-47742. 4. Install special tool GE-47742, with the A/C low pressure switch attached, onto the accumulator. Important Removing the seal from the A/C low pressure switch wire harness connector is required. Failure to remove the seal before plugging it into the switch will lead to misdiagnosis. The "plunger effect" of plugging the connector with a seal into the A/C low pressure switch induces a pressure on the back side of the switch. This pressure will skew the opening/closing characteristics of the switch 34-69 kPa (5-10 psi) until the pressure bleeds off. The time required for the connection induced pressure to bleed off can be 20 minutes or longer. 5. Remove the seal from the A/C low pressure switch wire harness connector. 6. Connect the wire harness, without the seal, to the A/C low pressure switch. 7. Connect the low side service hose from the ACR2000(R) or GE-48800 to the service port on special tool GE-47742. 8. Connect a Tech2(R) to the vehicle. 9. Start the vehicle and maintain an engine speed of 1500 RPM. Set the HVAC controls as follows: - Set the A/C control switch to ON. - Set the mode control switch to A/C and engage recirculation mode. - Set the blower motor speed to LOW. - Set the temperature control to full cold. - Set the auxiliary blower motor speed to LOW. If equipped. - Set the auxiliary temperature control to full cold. If equipped. - The vehicle must be operating with no sun load (in the shade). 10. Use the Tech2(R) to determine the A/C low pressure switch status and the ACR2000(R) or GE-48800 to determine the A/C low side pressure. Simultaneously monitor the switch status and the pressure at which the A/C low pressure switch opens and closes. The Tech2(R) will display switch status as "Normal" for Closed and "Low Pressure" for Open. A properly operating switch should open between 138-172 kPa (20-25 psi) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Air Conditioning - Diagnose A/C Low Pressure Switch > Page 12005 and close between 275-317 kPa (40-46 psi). 11. Remove special tool GE-47742 after diagnosis is complete. 12. Install a new O-ring on the A/C low pressure switch port on the accumulator. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. 13. Install the A/C low pressure switch onto the accumulator. Tighten Tighten the A/C low pressure switch to 6 Nm (44 lb in). Important Remember to install the seal back onto the A/C low pressure switch wire harness connector. Failure to replace the seal could result in terminal corrosion. 14. Reconnect the wire harness to the A/C low pressure switch. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 12006 Low Pressure Sensor / Switch: Locations Right Side Of The Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 12007 A/C Low Pressure Switch And A/C Accumulator Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 12008 Right Side Of Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Diagrams > HVAC System - Manual A/C Low Pressure Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Diagrams > HVAC System - Manual > Page 12011 A/C Low Pressure Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 12012 Low Pressure Sensor / Switch: Description and Operation A/C LOW PRESSURE SWITCH The A/C low pressure switch protects the A/C system from a low pressure condition that could damage the A/C compressor or cause evaporator icing. The HVAC control module applies 5 volts to the A/C low pressure switch signal circuit. The switch will open when the A/C low side pressure reaches 165-200 kPa (24-29 psi). This prevents the A/C compressor from operating. The switch will then close when A/C low pressure side reaches 275-310 kPa (40-45 psi). This enables the A/C compressor to turn back ON. The low pressure switch uses refrigerant pressure to open and close a set of electrical contacts. When A/C request is authorized, the switch is closed and shows normal status. During this state, the switch will show 0 volts on the A/C low pressure sensor signal circuit. When A/C request is denied due to a low pressure condition, the switch will be open. During this state, the switch will show 5 volts on the A/C low pressure sensor signal circuit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 12013 Low Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Remove the O-ring and discard. INSTALLATION PROCEDURE 1. Lightly coat the NEW O-ring seal with mineral base 525 viscosity refrigerant oil. 2. Install the NEW O-ring seal to the switch. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the A/C low pressure switch to the accumulator. Tighten Tighten the switch to 6 N.m (53 lb in). 4. Connect the electrical connector to the A/C low pressure switch. 5. Leak test the fittings of the components using the J 39400-A. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor Relay: > 03-01-38-015A > Oct > 08 > A/C - Blower Motor Runs After Vehicle Is Shut OFF Blower Motor Relay: Customer Interest A/C - Blower Motor Runs After Vehicle Is Shut OFF TECHNICAL Bulletin No.: 03-01-38-015A Date: October 27, 2008 Subject: HVAC Blower Motor May Run Continuously After Vehicle is Turned Off (Replace Blower Resistor Relay) Models: 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2004 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon XL with Manual Control HVAC (RPO CJ3) Built Prior to August, 2003 Supercede: This bulletin is being revised to update the parts information. Please discard Corporate Bulletin Number 03-01-38-015 (Section 01 - HVAC). Condition Some customers may comment on the HVAC blower motor running after the vehicle has been turned off. The blower may run for just a few minutes or continuously until the battery is discharged. Cause A new style HVAC blower relay/resistor may stick in the "on" position. When the HVAC fan blower relay has been energized, the contacts may "micro-weld" together. After this occurrence, the HVAC blower may not respond to the HVAC controller commands. Correction Replace the HVAC blower resistor/relay with the type used previous to the 2004 model year. The appropriate part numbers are listed in the table below. For specific repair procedures, refer to the 2004 Service Information (SI) under Blower Motor Resistor Assembly Replacement (SI Document ID # 526350 (C/K) or # 729996 (S/T). Parts Information Warranty Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Relay: > 03-01-38-015A > Oct > 08 > A/C - Blower Motor Runs After Vehicle Is Shut OFF Blower Motor Relay: All Technical Service Bulletins A/C - Blower Motor Runs After Vehicle Is Shut OFF TECHNICAL Bulletin No.: 03-01-38-015A Date: October 27, 2008 Subject: HVAC Blower Motor May Run Continuously After Vehicle is Turned Off (Replace Blower Resistor Relay) Models: 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2004 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon XL with Manual Control HVAC (RPO CJ3) Built Prior to August, 2003 Supercede: This bulletin is being revised to update the parts information. Please discard Corporate Bulletin Number 03-01-38-015 (Section 01 - HVAC). Condition Some customers may comment on the HVAC blower motor running after the vehicle has been turned off. The blower may run for just a few minutes or continuously until the battery is discharged. Cause A new style HVAC blower relay/resistor may stick in the "on" position. When the HVAC fan blower relay has been energized, the contacts may "micro-weld" together. After this occurrence, the HVAC blower may not respond to the HVAC controller commands. Correction Replace the HVAC blower resistor/relay with the type used previous to the 2004 model year. The appropriate part numbers are listed in the table below. For specific repair procedures, refer to the 2004 Service Information (SI) under Blower Motor Resistor Assembly Replacement (SI Document ID # 526350 (C/K) or # 729996 (S/T). Parts Information Warranty Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Service and Repair Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover from the underhood convenience center (1). 2. Remove the compressor relay (2). INSTALLATION PROCEDURE 1. Install the compressor relay (2). 2. Install the cover to the underhood convenience center (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Recalls: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: Recalls Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Recalls: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 12039 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Recalls: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 12040 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: Customer Interest A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set > Page 12046 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 12052 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 12053 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set > Page 12058 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Ticking Noise From Instrument Panel/DTC's Set Bulletin No.: 06-01-38-003 Date: April 27, 2006 TECHNICAL Subject: Intermittent Ticking Noise from I/P, Poor A/C Performance, HVAC DTCs B0229, B0414, B0424, B3770 (Reprogram HVAC Control Module) Models: 2004-2006 Cadillac Escalade Models 2004-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004-2006 GMC Sierra Models, Yukon Models with Air Conditioning (RPOs CJ2, CJ3) Condition Some customers may comment on one or more of the following concerns: ^ Intermittent ticking/clicking noise from the instrument panel. ^ Recirculation mode does not work or Air Conditioning (A/C) system performance is poor during high ambient temperatures. ^ Unable to control the driver side temperature. ^ Unable to control the passenger side temperature. ^ Unable to change the front system modes. Cause This condition may be caused by the Heating, Ventilation and Air Conditioning (HVAC) actuators that may hunt for the correct commanded position. This cycling may cause a clicking or ticking noise. An overtravel of the HVAC system control doors may cause one or more of the concerns listed above. If an overtravel occurs, a Diagnostic Trouble Code (DTC) will be set, and the door will go to a preset default position. When a system door defaults, that door will stay at the default position until the DTC is cleared. After the DTC is cleared, the door will operate properly until the overtravel condition re-occurs. The table lists the HVAC system doors and the DTC associated with it. Correction Technicians are to perform the normal diagnostic procedures in SI for these concerns. If diagnostics show that the HVAC system door(s) travel below 5 counts (out of the lower range) or above 250 counts (out of the upper range), then update the software calibrations in the HVAC control module. The new calibrations were made available to dealerships as part of TIS2000 incremental satellite update version 2.5, which was broadcast to dealers in February 2006. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 06-01-38-003 > Apr > 06 > A/C - Ticking Noise From Instrument Panel/DTC's Set > Page 12064 The new calibrations have been updated to compensate for the actuator overtravel condition, the actuator hunting and the ticking/clicking noises. The new calibrations effectively eliminate the codes listed above, the default position of the doors associated with the DTCs and opens up the feedback position value. The new calibrations should not be used unless the vehicle has one or more of the customer concerns listed above or a DTC listed above has been set. The new calibrations will not correct any other DTC or NC system performance concern. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 12070 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 11046 > Apr > 11 > Campaign - HVAC Blower Not Functional Runs Continuously > Page 12071 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 12072 Control Module HVAC: Locations HVAC Control Module Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 12073 Radio (With RPO Code UB7,Y91 Shown, Others Similar) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Manual Control Module HVAC: Diagrams HVAC System - Manual HVAC Control Module - C1 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Manual > Page 12076 HVAC Control Module - C1 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Manual > Page 12077 HVAC Control Module - C2 Part 1 HVAC Control Module - C2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Manual > Page 12078 Control Module HVAC: Diagrams HVAC System - Automatic HVAC Control Module - C1 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Manual > Page 12079 HVAC Control Module - C1 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Manual > Page 12080 HVAC Control Module - C2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > HVAC System - Manual > Page 12081 HVAC Control Module - C2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > HVAC System - Manual Control Module HVAC: Description and Operation HVAC System - Manual HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the above features. The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module used for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the above features. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > HVAC System - Manual > Page 12084 Control Module HVAC: Description and Operation HVAC System - Automatic HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the above features. HVAC CONTROL MODULE The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle mode master, provides a device on signal. The control module supports the above features. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic Control Module HVAC: Service and Repair HVAC System - Automatic Blower Motor Control Processor Replacement BLOWER MOTOR CONTROL PROCESSOR REPLACEMENT REMOVAL PROCEDURE 1. If equipped, remove the sound insulator panel. 2. Disconnect the electrical connector at the blower motor. 3. Disconnect the electrical connector (4) from the blower motor control processor (2). 4. Remove the blower motor control processor retaining screws (3) from the HVAC module (1). 5. Remove the blower motor control processor (2) from the HVAC module (1). INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 12087 1. Install the blower motor control processor (2) to the HVAC module (1). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the blower motor control processor retaining screws. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector (4) to the blower motor control processor (2). 4. Connect the electrical connector at the blower motor. 5. If equipped, install the sound insulator panel. HVAC Control Module Replacement HVAC CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 12088 1. Remove the instrument panel accessory trim plate. 2. Remove the screws from the HVAC control module. 3. Depress the control assembly retaining tabs and remove the HVAC control module from the instrument panel. 4. Disconnect the electrical connectors from the HVAC control module. INSTALLATION PROCEDURE IMPORTANT: The Key should be in the off position when connecting the electrical connectors to ensure proper calibration. 1. Connect the electrical connectors to the HVAC control module. 2. Install the HVAC control module into the instrument panel, ensuring that the HVAC control module retaining tabs lock into place. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws from the HVAC control module. Tighten Tighten the screws to 1.9 N.m (17 lb in). 4. Install the instrument panel accessory trim plate IMPORTANT: Do not adjust any controls on the HVAC control module while the HVAC control module is calibrating. If interrupted improper HVAC performance will result. 5. Start the vehicle and let run for one minute. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 12089 Control Module HVAC: Service and Repair HVAC System - Manual HVAC CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument cluster trim plate bezel. 2. Remove the instrument panel storage tray. 3. Remove the accessory switch assembly from the instrument panel. 4. Remove the screws from the HVAC control assembly. 5. Remove the HVAC control assembly, with the following procedure: 5.1. Release the retaining tabs. 5.2. Pull the control head out of the instrument panel carrier. 6. Disconnect the electrical connectors from the HVAC control assembly. INSTALLATION PROCEDURE IMPORTANT: The Key should be in the off position when connecting the electrical connectors to ensure proper calibration. 1. Connect the electrical connectors to the HVAC control assembly. 2. Install the HVAC control assembly. 3. Install the accessory switch assembly to the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws from the HVAC control assembly. Tighten Tighten the screws to 1.9 N.m (17 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC System - Automatic > Page 12090 5. Install the instrument panel storage tray. 6. Install the instrument cluster trim plate bezel. IMPORTANT: Do not adjust any controls on the HVAC control module while the HVAC control module is calibrating. If interrupted improper HVAC performance will result. 7. Start the vehicle and let run for one minute. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Air Temperature Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 12095 Ambient Air Temperature Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 12096 Ambient Temperature Sensor / Switch HVAC: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2-wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: Ambient Air Temperature Sensor - Inside Air Temperature Sensor Assembly - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Air Temperature Sensor A signal and a low-reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0.5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated under the above conditions. The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 12097 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the Park/Turn Signal. 2. Disconnect the electrical connector from the ambient air temperature sensor (3). 3. Remove the ambient air temperature sensor (3). INSTALLATION PROCEDURE 1. Install the ambient air temperature sensor (3). 2. Connect the electrical connector to the ambient air temperature sensor (3). 3. Install the Park/Turn Signal. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Diagrams Inside Air Temperature Sensor Assembly Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Diagrams > Page 12101 Cabin Temperature Sensor / Switch: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2-wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: Ambient Air Temperature Sensor - Inside Air Temperature Sensor Assembly - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Air Temperature Sensor A signal and a low-reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0.5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated under the above conditions. The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Diagrams > Page 12102 Cabin Temperature Sensor / Switch: Service and Repair INSIDE AIR TEMPERATURE SENSOR ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the left windshield garnish molding. 2. Remove the left center pillar assist handle. 3. Remove the left center pillar garnish molding. 4. Remove the left sunshade. 5. Gently pull down the headliner. 6. Disconnect the electrical connector from the inside air temperature sensor. 7. Partially remove the inside air temperature sensor from the headliner. 8. Remove the sensor grille from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. INSTALLATION PROCEDURE 1. Install the new sensor grille to the headliner. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Diagrams > Page 12103 2. Install the inside air temperature sensor to the headliner and sensor grille. 3. Connect the electrical connector to the inside air temperature sensor. 4. Install the left sunshade. 5. Install the left center pillar garnish molding. 6. Install the left center assist handle. 7. Install the left windshield garnish molding. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations Discharge Air Temperature Sensor / Switch: Locations Air Temperature Sensors - Upper Left And Right Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations > Page 12107 Air Temperature Sensors - Lower Left Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Locations > Page 12108 Air Temperature Sensors - Lower Right Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper Left Air Temperature Sensor - Upper Left Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper Left > Page 12111 Air Temperature Sensor - Upper Right Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper Left > Page 12112 Air Temperature Sensor - Lower Left Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Diagrams > Air Temperature Sensor - Upper Left > Page 12113 Air Temperature Sensor - Lower Right Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Diagrams > Page 12114 Discharge Air Temperature Sensor / Switch: Description and Operation AIR TEMPERATURE SENSORS The air temperature sensors are a 2-wire negative temperature co-efficient thermistor. The vehicle uses the following air temperature sensors: Ambient Air Temperature Sensor - Inside Air Temperature Sensor Assembly - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Air Temperature Sensor - Lower Right Air Temperature Sensor A signal and a low-reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal voltage decreases as the resistance decreases. The sensor operates within a temperature range between -40°C (-40°F) to 101°C (215°F). The sensor signal varies between 0.5 volts. The input of the duct air temperature sensors are different from the ambient and inside sensors. The HVAC control module converts the signal to a range between 0-255 counts. As the air temperature increases the count value will decrease. If the HVAC control module detects a malfunctioning sensor, then the control module software will use a defaulted air temperature value. The default value for the ambient and inside air temperature sensors will be displayed on the scan tool. The default value for the duct air temperature sensors will not be displayed on the scan tool. The scan tool parameter for the duct air temperature sensors are the actual state of the signal circuit. The default action ensures that the HVAC system can adjust the inside air temperature near the desired temperature until the condition is corrected. The ambient air temperature sensor mounts underhood and can be affected by city traffic, by idling, and by restarting a hot engine. Therefore, the HVAC control module filters the value of the ambient air temperature sensor for temperature display. The ambient air temperature value is updated under the above conditions. The scan tool has the ability to update the displayed ambient air temperature. To update the ambient air temperature display on the HVAC control module, perform the following procedure: Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. 1. Turn ON the ignition. 2. Simultaneously press the MODE, FRONT DEFROST and REAR DEFROST switches. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper Right Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Upper Right AIR TEMPERATURE SENSOR REPLACEMENT - UPPER RIGHT REMOVAL PROCEDURE 1. Remove the I/P upper trim panel. 2. Disconnect the electrical connector (1) from the upper right air temperature sensor (2). 3. Remove the upper right air temperature sensor (1) from the air distributor duct (3). INSTALLATION PROCEDURE 1. Install the upper right air temperature sensor (1) to the air distributor duct (3). 2. Connect the electrical connector (1) from the upper right air temperature sensor (2). 3. Install the I/P upper trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper Right > Page 12117 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Upper Left AIR TEMPERATURE SENSOR REPLACEMENT - UPPER LEFT REMOVAL PROCEDURE 1. Remove the upper left air temperature sensor (2) from the air distributor duct (1). 2. Disconnect the electrical connector (3) from the upper left air temperature sensor (2). INSTALLATION PROCEDURE 1. Install the upper left air temperature sensor (2) to the air distributor duct (1). 2. Connect the electrical connector (3) to the upper left air temperature sensor (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper Right > Page 12118 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower Left AIR TEMPERATURE SENSOR REPLACEMENT - LOWER LEFT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the lower left air temperature sensor (1). 2. Remove the lower left air temperature sensor (1) from the HVAC module (2). INSTALLATION PROCEDURE 1. Install the lower left air temperature sensor (1) to the HVAC module (2). 2. Connect the electrical connector to the lower left air temperature sensor (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Air Temperature Sensor Replacement - Upper Right > Page 12119 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower Right AIR TEMPERATURE SENSOR REPLACEMENT - LOWER RIGHT REMOVAL PROCEDURE 1. Remove the I/P lower closeout panel. 2. Remove the right floor duct. 3. Remove the center console. 4. Disconnect the electrical connector from the lower right air temperature sensor (1). 5. Remove the lower right air temperature sensor (1). INSTALLATION PROCEDURE 1. Install the lower right air temperature sensor (1). 2. Connect the electrical connector to the lower right air temperature sensor (1). 3. Install the center console. 4. Install the right floor duct. 5. Install the I/P lower closeout panel Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations Forward Lamp Harness Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Air Conditioning - Diagnose A/C Low Pressure Switch Low Pressure Sensor / Switch: Technical Service Bulletins Air Conditioning - Diagnose A/C Low Pressure Switch INFORMATION Bulletin No.: 04-01-38-010A Date: January 21, 2010 Subject: Diagnostic Information to Accurately Diagnose A/C Low Pressure Switch Using Kent Moore Special Tool GE-47742 Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2007 Chevrolet Silverado 2000-2006 Chevrolet Suburban, Tahoe 2002-2007 Chevrolet Avalanche 1999-2007 GMC Sierra 2000-2006 GMC Yukon, Yukon XL 2001-2006 GMC Yukon Denali XL 2001-2007 GMC Sierra Denali, Yukon Denali XL 2003-2008 HUMMER H2 with Air Conditioning Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 04-01-38-010 (Section 01 - HVAC). Currently, technicians cannot accurately determine the air conditioning (A/C) low pressure switch open/close pressure point by measuring pressure at the low side service port. This is because the evaporator is between the low side service port and the A/C low pressure switch. Correlating pressures measured at the low side service port to actual pressures at the A/C low pressure switch port is difficult because of the multiple variables that impact pressure drop across the evaporator. Providing a pressure range that would take into account all these variables would result in a pressure range that would be too broad to be useful for diagnostic purposes. Kent Moore special tool GE-47742 will allow technicians to monitor the actual pressures at which the A/C low pressure switch opens and closes under actual operating conditions. Technicians are to use the following steps to install and use Kent Moore special tool GE-47742 to measure A/C low pressure switch opening and closing pressures: 1. Disconnect the wire harness from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Install the A/C low pressure switch, using the threaded port with an O-ring, onto special tool GE-47742. 4. Install special tool GE-47742, with the A/C low pressure switch attached, onto the accumulator. Important Removing the seal from the A/C low pressure switch wire harness connector is required. Failure to remove the seal before plugging it into the switch will lead to misdiagnosis. The "plunger effect" of plugging the connector with a seal into the A/C low pressure switch induces a pressure on the back side of the switch. This pressure will skew the opening/closing characteristics of the switch 34-69 kPa (5-10 psi) until the pressure bleeds off. The time required for the connection induced pressure to bleed off can be 20 minutes or longer. 5. Remove the seal from the A/C low pressure switch wire harness connector. 6. Connect the wire harness, without the seal, to the A/C low pressure switch. 7. Connect the low side service hose from the ACR2000(R) or GE-48800 to the service port on special tool GE-47742. 8. Connect a Tech2(R) to the vehicle. 9. Start the vehicle and maintain an engine speed of 1500 RPM. Set the HVAC controls as follows: - Set the A/C control switch to ON. - Set the mode control switch to A/C and engage recirculation mode. - Set the blower motor speed to LOW. - Set the temperature control to full cold. - Set the auxiliary blower motor speed to LOW. If equipped. - Set the auxiliary temperature control to full cold. If equipped. - The vehicle must be operating with no sun load (in the shade). 10. Use the Tech2(R) to determine the A/C low pressure switch status and the ACR2000(R) or GE-48800 to determine the A/C low side pressure. Simultaneously monitor the switch status and the pressure at which the A/C low pressure switch opens and closes. The Tech2(R) will display switch status as "Normal" for Closed and "Low Pressure" for Open. A properly operating switch should open between 138-172 kPa (20-25 psi) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Air Conditioning - Diagnose A/C Low Pressure Switch > Page 12128 and close between 275-317 kPa (40-46 psi). 11. Remove special tool GE-47742 after diagnosis is complete. 12. Install a new O-ring on the A/C low pressure switch port on the accumulator. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. 13. Install the A/C low pressure switch onto the accumulator. Tighten Tighten the A/C low pressure switch to 6 Nm (44 lb in). Important Remember to install the seal back onto the A/C low pressure switch wire harness connector. Failure to replace the seal could result in terminal corrosion. 14. Reconnect the wire harness to the A/C low pressure switch. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 12129 Low Pressure Sensor / Switch: Locations Right Side Of The Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 12130 A/C Low Pressure Switch And A/C Accumulator Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 12131 Right Side Of Engine Compartment Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Diagrams > HVAC System Manual A/C Low Pressure Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Diagrams > HVAC System Manual > Page 12134 A/C Low Pressure Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 12135 Low Pressure Sensor / Switch: Description and Operation A/C LOW PRESSURE SWITCH The A/C low pressure switch protects the A/C system from a low pressure condition that could damage the A/C compressor or cause evaporator icing. The HVAC control module applies 5 volts to the A/C low pressure switch signal circuit. The switch will open when the A/C low side pressure reaches 165-200 kPa (24-29 psi). This prevents the A/C compressor from operating. The switch will then close when A/C low pressure side reaches 275-310 kPa (40-45 psi). This enables the A/C compressor to turn back ON. The low pressure switch uses refrigerant pressure to open and close a set of electrical contacts. When A/C request is authorized, the switch is closed and shows normal status. During this state, the switch will show 0 volts on the A/C low pressure sensor signal circuit. When A/C request is denied due to a low pressure condition, the switch will be open. During this state, the switch will show 5 volts on the A/C low pressure sensor signal circuit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 12136 Low Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Remove the O-ring and discard. INSTALLATION PROCEDURE 1. Lightly coat the NEW O-ring seal with mineral base 525 viscosity refrigerant oil. 2. Install the NEW O-ring seal to the switch. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the A/C low pressure switch to the accumulator. Tighten Tighten the switch to 6 N.m (53 lb in). 4. Connect the electrical connector to the A/C low pressure switch. 5. Leak test the fittings of the components using the J 39400-A. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations Ambient Light Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 12140 Solar Sensor: Diagrams Sunload Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 12141 Sunload Sensor (With RPO Code CJ2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 12142 Solar Sensor: Service and Repair SUN LOAD SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel (I/P) upper trim panel. 2. Remove the sun load sensor (2) from the upper trim panel. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the sun load sensor (2) to the upper trim panel. 3. Install the I/P upper trim panel- Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations Ambient Light Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 12146 Solar Sensor: Diagrams Sunload Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 12147 Sunload Sensor (With RPO Code CJ2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 12148 Solar Sensor: Service and Repair SUN LOAD SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel (I/P) upper trim panel. 2. Remove the sun load sensor (2) from the upper trim panel. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the sun load sensor (2) to the upper trim panel. 3. Install the I/P upper trim panel- Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Wiring Harness HVAC > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness HVAC: > 04-01-38-008 > Jun > 04 > A/C - Defaults To Defrost Mode/Poor Control Wiring Harness HVAC: Customer Interest A/C - Defaults To Defrost Mode/Poor Control Bulletin No.: 04-01-38-008 Date: June 17, 2004 TECHNICAL Subject: HVAC System Cannot be Controlled or Defaults to Defrost Mode (Repair HVAC Actuator Harness) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL Condition ^ Some customers may comment that they cannot control the HVAC (heating, ventilation and air conditioning) system. Others may comment that the HVAC system defaults to the Defrost mode. ^ Technicians may find that the following diagnostic trouble codes have set: ^ B0229 Recirculation Actuator ^ B0414 Left Air Temperature Actuator ^ B0424 Right Air Temperature Actuator ^ B3770 Mode Actuator Cause The HVAC actuator harness may contact a sharp edge on the instrument panel support brace, causing a rub through condition and a ground out of the actuator control and/or feedback circuits. Correction Locate the HVAC actuator harness contact point shown by the arrow in the above illustration. The illustration is of the instrument panel with the instrument panel compartment door opened and folded downward. The actuator harness is located in the left side of the opening in the instrument panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Wiring Harness HVAC > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness HVAC: > 04-01-38-008 > Jun > 04 > A/C - Defaults To Defrost Mode/Poor Control > Page 12157 Technicians are to inspect the HVAC actuator harness for contact with the instrument panel support brace. Repair any damage to the actuator harness wiring and install protective plastic conduit over the harness. Install friction tape over the sharp edge of the instrument panel brace. Clear the diagnostic trouble codes and verify proper HVAC system operation. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Wiring Harness HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness HVAC: > 04-01-38-008 > Jun > 04 > A/C Defaults To Defrost Mode/Poor Control Wiring Harness HVAC: All Technical Service Bulletins A/C - Defaults To Defrost Mode/Poor Control Bulletin No.: 04-01-38-008 Date: June 17, 2004 TECHNICAL Subject: HVAC System Cannot be Controlled or Defaults to Defrost Mode (Repair HVAC Actuator Harness) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL Condition ^ Some customers may comment that they cannot control the HVAC (heating, ventilation and air conditioning) system. Others may comment that the HVAC system defaults to the Defrost mode. ^ Technicians may find that the following diagnostic trouble codes have set: ^ B0229 Recirculation Actuator ^ B0414 Left Air Temperature Actuator ^ B0424 Right Air Temperature Actuator ^ B3770 Mode Actuator Cause The HVAC actuator harness may contact a sharp edge on the instrument panel support brace, causing a rub through condition and a ground out of the actuator control and/or feedback circuits. Correction Locate the HVAC actuator harness contact point shown by the arrow in the above illustration. The illustration is of the instrument panel with the instrument panel compartment door opened and folded downward. The actuator harness is located in the left side of the opening in the instrument panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Wiring Harness HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness HVAC: > 04-01-38-008 > Jun > 04 > A/C Defaults To Defrost Mode/Poor Control > Page 12163 Technicians are to inspect the HVAC actuator harness for contact with the instrument panel support brace. Repair any damage to the actuator harness wiring and install protective plastic conduit over the harness. Install friction tape over the sharp edge of the instrument panel brace. Clear the diagnostic trouble codes and verify proper HVAC system operation. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System Repairs and Inspections Required After a Collision: Service and Repair Air Bag System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION ACCIDENT WITH OR WITHOUT AIR BAG DEPLOYMENT - COMPONENT INSPECTIONS CAUTION: Proper operation of the SIR sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment in a collision or deployment for conditions less severe than intended. After any collision, inspect the following components as indicated. If you detect any damage, replace the component. If you detect any damage to the mounting points or mounting hardware, repair or replace the mounting points and mounting hardware as needed. Steering column.Perform the steering column accident damage checking procedures. Refer to Steering Column Accident Damage Inspection in Steering Wheel and Column. - I/P Knee Bolsters and Mounting Points.Inspect the knee bolsters for bending, twisting, buckling, or any other type of damage. - I/P brackets, braces, etc..Inspect for bending, twisting, buckling, or any other type of damage. - Seat Belts.Perform the seat belt operational and functional checks. Refer to Operational and Functional Checks in Seat Belts. - Seats and Seat Mounting Points. Inspect for bending, twisting, buckling, or any other type of damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 12169 Repairs and Inspections Required After a Collision: Service and Repair Seat Belt System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION CAUTION: Restraint systems can be damaged in a collision. To help avoid injury and ensure that all parts in need of replacement are replaced: - Replace any seat belt system that was in use during the collision serious enough to deploy any automatic restraint device such as air bags and seat belt pretensioners. This not only includes seat belt systems in use by people of adult size, but seat belt systems used to secure child restraints, infant carriers and booster seats, including LATCH system and top tether anchorages. - Replace any seat belt system that has torn, worn, or damaged components. This not only includes adult seat belt systems, but built-in child restraints and LATCH system components, if any. - Replace any seat belt system if you observe the words "REPLACE" or "CAUTION", or if a yellow tag is visible. Do not replace a seat belt if only the child seat caution label is visible. - Replace any seat belt system if you are doubtful about its condition. This not only includes adult seat belt systems, but built-in child restraints, LATCH system components, and any restraint system used to secure infant carriers, child restraints, and booster seats. Do NOT replace single seat belt system components in vehicles that have been in a collision as described above. Always replace the entire seat belt system with the buckle, guide and retractor assembly, which includes the latch and webbing material. After a minor collision where no automatic restraint device was deployed, seat belt system replacement may not be necessary, unless some of the parts are torn, worn, or damaged. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 12170 Repairs and Inspections Required After a Collision: Service and Repair Steering Column Steering Column Intermediate Shaft The redesigned steering column has a convoluted style intermediate shaft (Figs.1.22.and 1.23). The C1500 has one convoluted area, while all other models have two. These convoluted areas must be inspected for damage after every airbag deployment. Test the straightness of the shaft at various locations along the convoluted area by placing a straight edge against the intermediate shaft. The intermediate shaft must be replaced if bent or damaged. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling The SIR Identification Views shown below illustrate the approximate location of all SIR components available for the vehicle. This will assist in determining the appropriate SIR Disabling and Enabling for a given service procedure. Refer to See: Locations/SIR Zone Identification Views There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: - Do not expose inflator modules to temperatures above 65°C (150°F). - Verify the correct replacement part number. Do not substitute a component from a different vehicle. - Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: - Inflatable restraint sensing and diagnostic module (SDM) - Any Inflatable restraint air bag module - Inflatable restraint steering wheel module coil - Any Inflatable restraint sensor - Inflatable restraint seat belt pretensioners - Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Important: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. 4. Wait 1 minute before working on the system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 12175 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Customer Interest: > 05-09-41-001B > Jun > 08 > Restraints - SRS Lamp ON/Multiple DTC's are Set Air Bag Harness: Customer Interest Restraints - SRS Lamp ON/Multiple DTC's are Set TECHNICAL Bulletin No.: 05-09-41-001B Date: June 02, 2008 Subject: Supplemental Inflatable Restraint (SIR) Light ON, Diagnostic Trouble Codes (DTC) B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044 (Inspect and/or Replace IP Harness to Inflatable Restraint Module (Air Bag) Yellow 4-Way Connector C221 and/or C222) Models: 2003 - 2006 Cadillac Escalade Models 2003 - 2006 Chevrolet Avalanche, Suburban, Tahoe 2003 - 2007 Chevrolet Silverado (Classic Only) 2003 - 2006 GMC Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2003 - 2007 GMC Sierra (Classic Only) Supercede: This bulletin is being revised to add the 2007 model year for pickups and change a part number. Please discard Corporate Bulletin Number 05-09-41-001A (Section 09 - Restraints). Condition Some customers may comment that the Service Supplemental Inflatable Restraint Light is on. Diagnosis with a scan tool may indicate a DTC B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044. Cause The most likely cause of any one of the following DTCs: B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044 is improper connection/high resistance in the IP harness to inflatable restraint module connector C221 and/or C222. Diagnostic Information DTC B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044 will set when one of the following conditions occur: ^ The SDM detects the air bag module deployment loop resistance is greater than 4.8 ohms for 500 milliseconds. ^ The SDM detects that the voltage at the air bag module high control is less than 2.4 volts and deployment loop resistance is 6 ohms or greater for 500 milliseconds. ^ For additional diagnostic information, refer to DTC B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044 in the appropriate SI Document. Correction Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Refer to SIR Disabling and Enabling Zones. Failure to observe the correct procedure could cause deployment of the SIR components, personal injury, or unnecessary SIR system repairs. Important: The IP harness to inflatable restraint module connectors C221 or C222 is NOT located at the base of the steering column. ^ C221 (4 Cavities) - I/P Harness to Body Harness, behind the left kick panel ^ C222 (4 Cavities) (w/o HP2) - I/P harness to body harness, behind the right kick panel Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Customer Interest: > 05-09-41-001B > Jun > 08 > Restraints - SRS Lamp ON/Multiple DTC's are Set > Page 12185 ^ C222 (4 Cavities) (w/HP2) - Behind the left side I/P access panel ^ Refer to the Master Electrical Component List for additional location information. 1. Remove the appropriate side door sill plate. 2. Remove the appropriate side hinge pillar panel. 3. Locate the IP harness to inflatable restraint module yellow 4-way connector C221 or C222. 4. Inspect the IP harness to inflatable restraint module connector C221 or C222 for proper connection. 5. Disconnect and reconnect the IP harness to inflatable restraint module connector C221 or C222 THREE times. 6. Clear the DTC and road test the vehicle. ^ If DTCs B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044 DOES NOT reset, no additional repairs are necessary. Continue with step 10. ^ If DTCs B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044 DOES reset, the most likely cause is high resistance in the IP harness to inflatable restraint module connector C221 or C222. Continue with the next step. 7. Replace the appropriate connector C221 and/or C222, P/N's 15306186 and 88987998. Refer to SIR/SRS Wiring Repairs (SI Document ID #325229). 8. Road test the vehicle and confirm that the repair is complete. 9. Install the driver's side hinge pillar panel. 10. Install the driver's side door sill plate. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-09-41-001B > Jun > 08 > Restraints - SRS Lamp ON/Multiple DTC's are Set Air Bag Harness: All Technical Service Bulletins Restraints - SRS Lamp ON/Multiple DTC's are Set TECHNICAL Bulletin No.: 05-09-41-001B Date: June 02, 2008 Subject: Supplemental Inflatable Restraint (SIR) Light ON, Diagnostic Trouble Codes (DTC) B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044 (Inspect and/or Replace IP Harness to Inflatable Restraint Module (Air Bag) Yellow 4-Way Connector C221 and/or C222) Models: 2003 - 2006 Cadillac Escalade Models 2003 - 2006 Chevrolet Avalanche, Suburban, Tahoe 2003 - 2007 Chevrolet Silverado (Classic Only) 2003 - 2006 GMC Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2003 - 2007 GMC Sierra (Classic Only) Supercede: This bulletin is being revised to add the 2007 model year for pickups and change a part number. Please discard Corporate Bulletin Number 05-09-41-001A (Section 09 - Restraints). Condition Some customers may comment that the Service Supplemental Inflatable Restraint Light is on. Diagnosis with a scan tool may indicate a DTC B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044. Cause The most likely cause of any one of the following DTCs: B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044 is improper connection/high resistance in the IP harness to inflatable restraint module connector C221 and/or C222. Diagnostic Information DTC B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044 will set when one of the following conditions occur: ^ The SDM detects the air bag module deployment loop resistance is greater than 4.8 ohms for 500 milliseconds. ^ The SDM detects that the voltage at the air bag module high control is less than 2.4 volts and deployment loop resistance is 6 ohms or greater for 500 milliseconds. ^ For additional diagnostic information, refer to DTC B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044 in the appropriate SI Document. Correction Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Refer to SIR Disabling and Enabling Zones. Failure to observe the correct procedure could cause deployment of the SIR components, personal injury, or unnecessary SIR system repairs. Important: The IP harness to inflatable restraint module connectors C221 or C222 is NOT located at the base of the steering column. ^ C221 (4 Cavities) - I/P Harness to Body Harness, behind the left kick panel ^ C222 (4 Cavities) (w/o HP2) - I/P harness to body harness, behind the right kick panel Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-09-41-001B > Jun > 08 > Restraints - SRS Lamp ON/Multiple DTC's are Set > Page 12191 ^ C222 (4 Cavities) (w/HP2) - Behind the left side I/P access panel ^ Refer to the Master Electrical Component List for additional location information. 1. Remove the appropriate side door sill plate. 2. Remove the appropriate side hinge pillar panel. 3. Locate the IP harness to inflatable restraint module yellow 4-way connector C221 or C222. 4. Inspect the IP harness to inflatable restraint module connector C221 or C222 for proper connection. 5. Disconnect and reconnect the IP harness to inflatable restraint module connector C221 or C222 THREE times. 6. Clear the DTC and road test the vehicle. ^ If DTCs B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044 DOES NOT reset, no additional repairs are necessary. Continue with step 10. ^ If DTCs B0013, B0014, B0017, B0018, B0024, B0026, B0043, B0044 DOES reset, the most likely cause is high resistance in the IP harness to inflatable restraint module connector C221 or C222. Continue with the next step. 7. Replace the appropriate connector C221 and/or C222, P/N's 15306186 and 88987998. Refer to SIR/SRS Wiring Repairs (SI Document ID #325229). 8. Road test the vehicle and confirm that the repair is complete. 9. Install the driver's side hinge pillar panel. 10. Install the driver's side door sill plate. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > NHTSA04V045000 > Feb > 04 > Recall 04V045000: Possible Hydro-Boost Defect Power Steering Pump: All Technical Service Bulletins Recall 04V045000: Possible Hydro-Boost Defect DEFECT: Certain sport utility vehicles, pickup trucks, and passenger vans fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 135, "Passenger Car Brake Systems." Some of these vehicles were produced with an out-of-specification brake hydro-boost housing relief valve bore. Consequently, the valve O-ring seal may fracture. Steering efforts may be slightly increased while braking or parking. Under certain driving conditions, a fractured seal may also require an increase in the applied brake pedal effort to achieve the same vehicle deceleration. REMEDY: Dealers are to replace the hydro-boost relief valve. The manufacturer has reported that owner notification is expected to begin during the second quarter of 2004. Owners may contact Cadillac at 1-866-982-2339; Chevrolet at 1-800-630-2438; GMC at 1-866-996-9463; or Hummer at 1-866-486-6376. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations Below Driver Seat - Restraint Systems Wiring Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 12205 Inflatable Restraint Sensing And Diagnostic Module: Diagrams Inflatable Restraint Sensing and Diagnostic Module (SDM) - Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 12206 Inflatable Restraint Sensing and Diagnostic Module (SDM) - Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 12207 Inflatable Restraint Sensing and Diagnostic Module (SDM) - Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 12208 Inflatable Restraint Sensing And Diagnostic Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The sensing and diagnostic module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at various locations on the vehicle. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors. The SDM compares the results of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and requests the instrument panel cluster (IPC) to turn the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will request the IPC to turn the AIR BAG indicator ON. In the event that ignition 1 voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important to note, when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 12209 Inflatable Restraint Sensing And Diagnostic Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 7. 2. Remove the drivers seat. 3. Remove the driver side door sill plate. 4. Fold back the carpet to access the inflatable restraint sensing and diagnostic module (SDM). 5. Remove the connector position assurance (CPA) (1) from the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the open position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 12210 7. Disconnect the SDM wiring harness connector (1) from the SDM (3). 8. Remove the SDM mounting fasteners. 9. Remove the SDM from the vehicle. IMPORTANT: The following repair procedures should only be used in the event that the inflatable restraint sensing and diagnostic module (SDM) mounting studs and/or fasteners are damaged to the extent that the SDM may no longer be properly mounted. 10. Repair the fasteners using the following procedure: 10.1. Remove the stripped nut and discard the nut. 10.2. Drill out the weld spots to the weld stud from the floor pan side, then remove and discard the stud. 10.3. Condition the floor panel attaching surface where the new stud is to be installed. 10.4. Install new weld stud GM P/N 115115602 and clamp the weld stud. 10.5. Migweld the stud at the drilled holes from above or below the floor pan, as required. 10.6. Apply body sealer GM P/N 9984248 around any exposed openings. 10.7. Install a new fastener GM P/N 11515933. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other contaminants from the mounting surface. 2. Install the SDM (3) horizontally to the vehicle. 3. Point the arrow on the SDM toward the front of the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the SDM mounting fasteners. Tighten Tighten fasteners to 10 N.m (89 lb in). 5. Connect the SDM wiring harness connector (1) to the SDM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 12211 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the close position. 7. Install the connector position assurance (CPA) (1) to the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 8. Position the carpet to cover the inflatable restraint sensing and diagnostic module (SDM). 9. Install the door sill plate. 10. Install the driver seat. IMPORTANT: The AIR BAG indicator may remain ON after the SDM has been replaced. DTC B1001 may set requiring the SDM part number to be set in multiple modules. If the indicator remains ON after enabling the SIR system, perform the diagnostic system check and follow the steps thoroughly to ensure that the SDM is set properly. 11. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 7. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations Center of the I/P - Accessory Switches Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 12215 Inflatable Restraint I/P Module Disable Switch (With RPO Code C99) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Inflatable Restraint I/P Module Disable Switch (HD Model) Air Bag Deactivation Switch: Description and Operation Inflatable Restraint I/P Module Disable Switch (HD Model) INFLATABLE RESTRAINT I/P MODULE DISABLE SWITCH (HD MODEL PICKUPS) The instrument panel (I/P) module disable switch is a manual 2-position key switch. The I/P module disable switch allows the vehicle operator the ability to enable or disable the I/P module (passenger frontal air bag). The I/P module disable switch interfaces with the inflatable restraint sensing and diagnostic module (SDM) to request the enabling or disabling of the I/P module. The occupants are notified of the enabling or disabling of the I/P module via the I/P module disable switch ON/OFF indicators located on the I/P module disable switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Inflatable Restraint I/P Module Disable Switch (HD Model) > Page 12218 Air Bag Deactivation Switch: Description and Operation Inflatable Restraint I/P Module Disable Switch INFLATABLE RESTRAINT I/P MODULE DISABLE SWITCH The instrument panel (I/P) module disable switch is a manual 2-position key switch. The I/P module disable switch allows the vehicle operator the ability to enable or disable the I/P module (passenger frontal air bag). The I/P module disable switch interfaces with the passenger presence system (PPS) module to request the enabling or disabling of the I/P module. The occupants are notified of the enabling or disabling of the I/P module via the I/P module disable switch ON/OFF indicator and the PASSENGER AIR BAG ON/OFF indicators located on the rear view mirror. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Page 12219 Air Bag Deactivation Switch: Service and Repair INFLATABLE RESTRAINT INSTRUMENT PANEL (I/P) MODULE DISABLE SWITCH REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Service Precautions. 1. Remove the instrument panel trim bezel. 2. Remove the I/P module switch from the lower right opening of the switch plate panel. 3. Disconnect the I/P module switch electrical connector. INSTALLATION PROCEDURE 1. Connect the I/P module switch electrical connector. 2. Install the I/P module switch into the lower right opening of the switch plate panel. 3. Install the instrument panel trim bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation Clockspring Assembly / Spiral Cable: Description and Operation INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL The steering wheel module coil is attached to the steering column and is located under the steering wheel. The steering wheel module coil consists of two or more current-carrying coils. The coils allow the rotation of the steering wheel while maintaining continuous electrical contact between the driver deployment loop and the steering wheel module. Four coil wires are used for the steering wheel module deployment loop. Additional coil wires are used for accessories attached to the steering wheel depending on the vehicle model. The steering wheel module coil connector is located near the base of the steering column. The connector contains a shorting bar that shorts the steering wheel module coil deployment loop circuitry to prevent unwanted deployment of the air bag when it is disconnected. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Page 12223 Clockspring Assembly / Spiral Cable: Service and Repair INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3. 2. Remove the steering column trim covers. 3. Remove the wire harness assembly (4) from the wire harness strap (5). 4. Remove the 2 wire harness straps (3) from the wire harness assembly. 5. Remove the wire harness strap (2) from the upper tilt head assembly (1). 6. Remove the retaining ring (1). 7. Remove the SIR coil (2). 8. Remove the wave washer (3) from the steering column upper shaft. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Page 12224 1. Align the block tooth on the upper shaft to the 12 o'clock position (1). NOTE: Ensure all fasteners are securely seated before applying needed torque. Failure to do so may result in component damage or malfunctioning of steering column. 2. Install the wave washer (1) to the steering column upper shaft. 3. A new SIR coil assembly will come pre-centered. However if centering is required, refer to Inflatable Restraint Steering Wheel Module Coil Centering in Steering Wheel and Column. 4. Align the SIR coil (2) with the horn tower on the turn signal cancel cam (1) IMPORTANT: Do not remove the tab on the SIR coil until installation is complete. 5. Install the pre-centered SIR coil (2) to the steering column upper shaft. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Page 12225 6. Remove and discard the centering tab (1). NOTE: Gently pull on the lower coil assembly wire in order to remove any wire kinks inside of the column assembly. Verify that there are NO kinks or bends in the SIR coil assembly wire. If a kink or bend is present, interference may occur with the shaft lock mechanism. Turning the steering wheel may cut or damage the wire. 7. Install the retaining ring (1). Verify that the ring (1) is firmly seated in the groove on the upper shaft (2). 8. Install the wire harness assembly (4) into the wire strap (5). 9. Install the wire harness strap (2) into the upper tilt head assembly (1). 10. Install wire harness straps (3) to the wire harness assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Page 12226 11. Install the steering column trim covers. 12. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations Front End Sensors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 12230 Right Side Impact Sensor (With RPO Code HP2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 12231 Impact Sensor: Diagrams Inflatable Restraint Front End Sensor - Left Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 12232 Inflatable Restraint Front End Sensor - Right Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 12233 Inflatable Restraint Front End Sensor (With RPO Code HVY) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 12234 Inflatable Restraint Side Impact Sensor (SIS) - Right (With RPO Code HP2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Front End Sensors Impact Sensor: Description and Operation Front End Sensors INFLATABLE RESTRAINT FRONT END SENSORS The front end sensors are equipped on vehicles to supplement the SIR system performance. The front end sensors are electronic and are not part of the deployment loops, but instead provide inputs to the sensing and diagnostic module (SDM). The front end sensors can assist in determining the severity of some frontal collisions. The SDM uses the input from the front end sensors to assist in determining the severity of a frontal collision further supporting air bag deployment. If the SDM determines a deployment is warranted, the SDM will cause current to flow through the deployment loops deploying the frontal air bags. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Front End Sensors > Page 12237 Impact Sensor: Description and Operation Side Impact Sensor (SIS) (Right) With RPO HP2 INFLATABLE RESTRAINT SIDE IMPACT SENSOR (SIS) (RIGHT) WITH RPO HP2 The right side impact sensor (SIS) contains a sensing device which monitors vehicle acceleration and velocity changes to detect side collisions that are severe enough to warrant disabling the 42-volt system. The SIS is not part of the deployment loop, but instead provides an input to the sensing and diagnostic module (SDM). When the SDM receives a signal from the SIS that a collision has occurred, the SDM communicates this over the vehicles communication bus. The module responsible for the 42-volt system receives this message and disables the 42-volt system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Sensor: Service and Repair Front INFLATABLE RESTRAINT FRONT END SENSOR REPLACEMENT REMOVAL PROCEDURE CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1. 2. Disconnect the electrical connector. 3. Remove the connector position assurance (CPA) from the connector. 4. Remove the sensor bolt. 5. Remove the sensor (2) from the vehicle. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other contaminants from the mounting surface (1). IMPORTANT: Refer to SIR Service Precautions. 2. Point the arrow on the sensor toward the front of the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the sensor (2) horizontally to the radiator support. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 12240 Tighten Tighten the bolt to 9 N.m (79 lb in). 4. Connect the electrical connector to the sensor (2). 5. Install the CPA. 6. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 12241 Impact Sensor: Service and Repair Side INFLATABLE RESTRAINT SIDE IMPACT SENSOR REPLACEMENT REMOVAL PROCEDURE CAUTION: - Refer to SIR Inflator Module Handling and Storage Caution in Service Precautions. - When carrying an undeployed inflatable restraint seat belt pretensioner: - Do not carry the seat belt pretensioner by the wires or connector. - Carry the seat belt pretensioner by the piston tube, keeping hands and fingers away from the cable. - Make sure the open end of the seat belt pretensioner piston tube points away from you and other people. - Do not cover the seat belt pretensioner piston tube opening with your hand. Failure to observe these guidelines may result in personal injury. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 6. 2. Remove the front door trim panel. 3. Loosen the 2 inflatable restraint side impact sensor fasteners (2). 4. Remove the inflatable restraint side impact sensor (1) from the door (4). 5. Remove the connector position assurance (CPA) (3), and disconnect the inflatable restraint side impact sensor yellow 2-way harness connector (5). INSTALLATION PROCEDURE 1. Connect the inflatable restraint side impact sensor yellow 2-way harness connector (5) to the inflatable restraint side impact sensor (1). 2. Install the CPA (3) to the inflatable restraint side impact sensor yellow 2-way connector (5). 3. Install the inflatable restraint side impact sensor (1) to the door (4). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 12242 NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the fasteners (2) to the inflatable restraint side impact sensor (1) using only hand tools. Tighten Tighten the fasteners to 10 N.m (89 lb in). 5. Install the door trim panel. 6. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 6. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 12243 Impact Sensor: Service and Repair Sensor Replacement Guidelines SENSOR REPLACEMENT GUIDELINES The SIR sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. For example, a moderate collision where the front of the vehicle impacts a tree. If the vehicle has an SIR sensor mounted forward of the radiator, it must be replaced. - Replace the sensor whether or not the air bags have deployed. - Replace the sensor even if it appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR sensing system. Do not try to determine whether the sensor is undamaged, replace the sensor. Also, if you follow a Diagnostic Trouble Code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set Seat Occupant Sensor: Customer Interest SRS - Air Bag Lamp ON/DTC B0092 Set Bulletin No.: 02-09-41-002A Date: March 24, 2004 TECHNICAL Subject: Air Bag Lamp On, Passenger Air Bag Indicator Always Reads OFF, DTC B0092 Set (Repair Passenger Presence System (PPS) Sensor Harness) Models: 2003-2004 Cadillac Escalade, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon XL with Sensor Indicator Inflatable Restraint Front Passenger/Child Presence Detector (RPO ALO) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 02-09-41-002 (Section 09 - Restraints). Condition Some customers may comment that the Air Bag Lamp is on and the Passenger Air Bag indicator always reads OFF. Upon investigation, the technician may find DTC B0092 set. Cause The cause of this condition may be a shorted Passenger Presence System (PPS) sensor wire. The PPS sensor harness is located under the front passenger seat. This harness may be pinched between the seat frame and the track/riser. Correction Locate the PPS sensor (1) and inspect the harness for proper routing. If the harness is pinched between the seat frame and the track/riser, use the procedure listed below to repair wire(s). 1. Move the front passenger seat to the full rearward and full tilt up position. 2. Loosen the seat frame to track/riser nut and remove the harness. 3. Tighten the seat frame to track/riser nut. 4. Repair any damaged wires. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set > Page 12252 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-08-50-009F > Dec > 10 > Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set Seat Occupant Sensor: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC B0092 Set Bulletin No.: 02-09-41-002A Date: March 24, 2004 TECHNICAL Subject: Air Bag Lamp On, Passenger Air Bag Indicator Always Reads OFF, DTC B0092 Set (Repair Passenger Presence System (PPS) Sensor Harness) Models: 2003-2004 Cadillac Escalade, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon XL with Sensor Indicator Inflatable Restraint Front Passenger/Child Presence Detector (RPO ALO) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 02-09-41-002 (Section 09 - Restraints). Condition Some customers may comment that the Air Bag Lamp is on and the Passenger Air Bag indicator always reads OFF. Upon investigation, the technician may find DTC B0092 set. Cause The cause of this condition may be a shorted Passenger Presence System (PPS) sensor wire. The PPS sensor harness is located under the front passenger seat. This harness may be pinched between the seat frame and the track/riser. Correction Locate the PPS sensor (1) and inspect the harness for proper routing. If the harness is pinched between the seat frame and the track/riser, use the procedure listed below to repair wire(s). 1. Move the front passenger seat to the full rearward and full tilt up position. 2. Loosen the seat frame to track/riser nut and remove the harness. 3. Tighten the seat frame to track/riser nut. 4. Repair any damaged wires. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set > Page 12262 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Occupant Sensor: > 06-08-50-009F > Dec > 10 > Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation Malfunction Lamp / Indicator: Description and Operation AIR BAG INDICATOR The AIR BAG indicator, located on the instrument panel cluster (IPC) is used to notify the driver of SIR system malfunctions and to verify that the sensing and diagnostic module (SDM) is communicating with the IPC. When the ignition is turned ON, the SDM is supplied with ignition 1 voltage and requests the IPC to flash the AIR BAG indicator 7 times. While flashing the indicator, the SDM conducts test on all SIR system components and circuits. If no malfunctions are detected the SDM will communicate with the IPC through the class 2 serial data circuit and request the IPC to turn the AIR BAG indicator OFF. The SDM provides continuous monitoring of the air bag circuits by conducting a sequence of checks. If a malfunction is detected the SDM will store a DTC and request the IPC to turn the AIR BAG indicator ON. The presence of a SIR system malfunction could result in non-deployment of the air bags. The AIR BAG indicator will remain ON until the malfunction has been repaired. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Recalls for Child Seat: > NHTSA04V225000 > May > 04 > Recall 04V225000: Child Seat Anchorage Non-Compliance Child Seat: Recalls Recall 04V225000: Child Seat Anchorage Non-Compliance Make / Models : Model/Build Years: Chevrolet / Express 2003 Chevrolet / Silverado 2003-2004 GMC / Savana 2003 GMC / Sierra 2003-2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID Number : 04V225000 Recall Date : MAY 10, 2004 COMPONENT: Seat Belts: Front: Anchorage Potential Number Of Units Affected : 736 SUMMARY: certain extended and regular cab pickup trucks and cargo vans converted to compressed natural gas (CNG) fail to conform to the requirements of Federal Motor Vehicle Safety Standard NO. 225, "Child Restraint Anchorage Systems." These vehicles have one seating position, the center rear seat, equipped with child restraint lower anchorages. CONSEQUENCE: The standard requires child seat lower anchorages in two seating positions for vehicles with three rear seating positions. The standard cab and cargo van vehicles, which only have front seating positions, have an air bag off switch to disable the front passenger air bag and do not have child restraint lower anchorages in the passenger seat. The standard requires passenger seat child seat lower anchorages in vehicles with an air bag off switch. however, the standard does not require vehicles with only front seating positions to have lower anchorage provisions if the vehicle is not equipped with an air bag off switch. REMEDY: To bring the standard cab and cargo van vehicles into compliance, dealers will inject epoxy into the air bag off switch to prevent air bag activation, relocate the switch behind the instrument panel and then install a cover over the resulting opening. The sun visor label and owner's manual will also be changed. the correction for the extended cab vehicle will consist of changing the front passenger seat to a seat that has child restraint lower anchorages. The recall began on September 9, 2004. Owners should contact Chevrolet at 1-800-630-2438 OR GMC AT 1-866-996-9463. NOTES: GM Recall NO. 04038. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat: > NHTSA04V225000 > May > 04 > Recall 04V225000: Child Seat Anchorage Non-Compliance Child Seat: All Technical Service Bulletins Recall 04V225000: Child Seat Anchorage Non-Compliance Make / Models : Model/Build Years: Chevrolet / Express 2003 Chevrolet / Silverado 2003-2004 GMC / Savana 2003 GMC / Sierra 2003-2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID Number : 04V225000 Recall Date : MAY 10, 2004 COMPONENT: Seat Belts: Front: Anchorage Potential Number Of Units Affected : 736 SUMMARY: certain extended and regular cab pickup trucks and cargo vans converted to compressed natural gas (CNG) fail to conform to the requirements of Federal Motor Vehicle Safety Standard NO. 225, "Child Restraint Anchorage Systems." These vehicles have one seating position, the center rear seat, equipped with child restraint lower anchorages. CONSEQUENCE: The standard requires child seat lower anchorages in two seating positions for vehicles with three rear seating positions. The standard cab and cargo van vehicles, which only have front seating positions, have an air bag off switch to disable the front passenger air bag and do not have child restraint lower anchorages in the passenger seat. The standard requires passenger seat child seat lower anchorages in vehicles with an air bag off switch. however, the standard does not require vehicles with only front seating positions to have lower anchorage provisions if the vehicle is not equipped with an air bag off switch. REMEDY: To bring the standard cab and cargo van vehicles into compliance, dealers will inject epoxy into the air bag off switch to prevent air bag activation, relocate the switch behind the instrument panel and then install a cover over the resulting opening. The sun visor label and owner's manual will also be changed. the correction for the extended cab vehicle will consist of changing the front passenger seat to a seat that has child restraint lower anchorages. The recall began on September 9, 2004. Owners should contact Chevrolet at 1-800-630-2438 OR GMC AT 1-866-996-9463. NOTES: GM Recall NO. 04038. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Description and Operation Knee Diverter: Description and Operation DRIVER AND PASSENGER KNEE BOLSTERS The knee bolsters are designed to help restrain the lower torsos of front seat occupants by absorbing energy through the front seat occupants' upper legs. In a frontal collision, the front seat occupants' legs may come in contact with the knee bolsters. The knee bolsters are designed to crush or deform, absorbing some of the impact, which helps to reduce bodily injuries. The driver and passenger knee bolsters are located in the lower part of the I/P and must be inspected for damage after a collision. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Description and Operation > Page 12291 Knee Diverter: Service and Repair KNEE BOLSTER REPLACEMENT REMOVAL PROCEDURE 1. Remove the I/P cluster trim plate bezel. 2. Remove the knee bolster screws. 3. Unsnap the top of the knee bolster from the I/P assembly. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Description and Operation > Page 12292 1. Snap the top of the knee bolster into the I/P assembly. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the knee bolster screws. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the I/P cluster trim plate bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations Below Driver Seat - Restraint Systems Wiring Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 12297 Inflatable Restraint Sensing And Diagnostic Module: Diagrams Inflatable Restraint Sensing and Diagnostic Module (SDM) - Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 12298 Inflatable Restraint Sensing and Diagnostic Module (SDM) - Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 12299 Inflatable Restraint Sensing and Diagnostic Module (SDM) - Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 12300 Inflatable Restraint Sensing And Diagnostic Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The sensing and diagnostic module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at various locations on the vehicle. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors. The SDM compares the results of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and requests the instrument panel cluster (IPC) to turn the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will request the IPC to turn the AIR BAG indicator ON. In the event that ignition 1 voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important to note, when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 12301 Inflatable Restraint Sensing And Diagnostic Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 7. 2. Remove the drivers seat. 3. Remove the driver side door sill plate. 4. Fold back the carpet to access the inflatable restraint sensing and diagnostic module (SDM). 5. Remove the connector position assurance (CPA) (1) from the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the open position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 12302 7. Disconnect the SDM wiring harness connector (1) from the SDM (3). 8. Remove the SDM mounting fasteners. 9. Remove the SDM from the vehicle. IMPORTANT: The following repair procedures should only be used in the event that the inflatable restraint sensing and diagnostic module (SDM) mounting studs and/or fasteners are damaged to the extent that the SDM may no longer be properly mounted. 10. Repair the fasteners using the following procedure: 10.1. Remove the stripped nut and discard the nut. 10.2. Drill out the weld spots to the weld stud from the floor pan side, then remove and discard the stud. 10.3. Condition the floor panel attaching surface where the new stud is to be installed. 10.4. Install new weld stud GM P/N 115115602 and clamp the weld stud. 10.5. Migweld the stud at the drilled holes from above or below the floor pan, as required. 10.6. Apply body sealer GM P/N 9984248 around any exposed openings. 10.7. Install a new fastener GM P/N 11515933. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other contaminants from the mounting surface. 2. Install the SDM (3) horizontally to the vehicle. 3. Point the arrow on the SDM toward the front of the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the SDM mounting fasteners. Tighten Tighten fasteners to 10 N.m (89 lb in). 5. Connect the SDM wiring harness connector (1) to the SDM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 12303 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the close position. 7. Install the connector position assurance (CPA) (1) to the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 8. Position the carpet to cover the inflatable restraint sensing and diagnostic module (SDM). 9. Install the door sill plate. 10. Install the driver seat. IMPORTANT: The AIR BAG indicator may remain ON after the SDM has been replaced. DTC B1001 may set requiring the SDM part number to be set in multiple modules. If the indicator remains ON after enabling the SIR system, perform the diagnostic system check and follow the steps thoroughly to ensure that the SDM is set properly. 11. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 7. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling The SIR Identification Views shown below illustrate the approximate location of all SIR components available for the vehicle. This will assist in determining the appropriate SIR Disabling and Enabling for a given service procedure. Refer to See: Air Bag Systems/Locations/SIR Zone Identification Views There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: - Do not expose inflator modules to temperatures above 65°C (150°F). - Verify the correct replacement part number. Do not substitute a component from a different vehicle. - Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: - Inflatable restraint sensing and diagnostic module (SDM) - Any Inflatable restraint air bag module - Inflatable restraint steering wheel module coil - Any Inflatable restraint sensor - Inflatable restraint seat belt pretensioners - Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Important: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 12308 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair Child Seat Tether Attachment: Service and Repair CHILD RESTRAINT TETHER ANCHOR REPLACEMENT The child restraint tether anchors are welded to the seat back frame and cannot be serviced separately. Refer to Seat Back Frame Replacement - Front or Seat Back Frame Replacement Rear in Seats. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 05037 > Jul > 05 > Recall - 2nd Row Center Seat Belt Loop Modification Technical Service Bulletin # 05037 Date: 050714 Recall - 2nd Row Center Seat Belt Loop Modification Second Row Center Safety Belt # 05037 - (Jul 14, 2005) Models: 2003-2005 CADILLAC ESCALADE, ESCALADE ESV, ESCALADE EXT 2003-2005 CHEVROLET AVALANCIE, SILVERADO CREW CAB, SUBURBAN, TAHOE 2003-2005 GMC SIERRA CREW CAB, YUKON, YUKON XL 2004-2005 HUMMER H2 Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado Crew Cab, Suburban, Tahoe; GMC Sierra Crew Cab, Yukon, Yukon XL; and 2004-2005 HUMMER H2 vehicles. On these vehicles, the seat loop in the second row center seating position may make it difficult to position the lap portion of the safety belt low around the hips of the occupant. In the event of a vehicle accident, if the lap portion of the safety belt routing is not low and snug on the hips, it may not properly restrain the occupant and could increase the risk of abdominal injury. Correction Dealers are to eliminate the seat loop by removing the safety belt from the loop and stitching the loop closed. Vehicles Involved Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 05037 > Jul > 05 > Recall - 2nd Row Center Seat Belt Loop Modification > Page 12321 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 05037 > Jul > 05 > Recall - 2nd Row Center Seat Belt Loop Modification > Page 12322 Involved are certain 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado Crew Cab, Suburban, Tahoe; GMC Sierra Crew Cab, Yukon, Yukon XL; and 2004-2005 HUMMER H2 vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US and Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicle, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 05037 > Jul > 05 > Recall - 2nd Row Center Seat Belt Loop Modification > Page 12323 Service Procedure 1. Note the position of the rear seats. 2. Position the seats to gain access to the lower seat belt anchor stud for the rear center seat. 3. Remove any cover necessary to gain access to the lower seat belt anchor point for the rear center seat. 4. Remove the nut (1) retaining the rear center seat's lower seat belt anchor (seat back shown in the up position). 5. Remove the belt anchor point from the stud. 6. Remove the belt from the seat loop on the front of the seat back cushion. 7. Route the belt outside of the seat loop and install it on the lower anchor stud. Be sure that the belt is not twisted. 8. Install the retaining nut to the anchor stud. Tighten Tighten the retaining nut to 53 Nm (39 lb ft). 9. Using an appropriate color of locally obtained upholstery thread and needle (size 16 recommended), sew the retaining loop closed in the center. 10. Reposition the seats to the customer's original position as noted in Step 1 Courtesy Transportation -- for US and Canada The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 05037 > Jul > 05 > Recall - 2nd Row Center Seat Belt Loop Modification > Page 12324 Policies and Procedures Manual for courtesy transportation guidelines. Claim Information Submit a Product Recall Claim with the information shown. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown this bulletin). Customer Notification -- For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 05037 > Jul > 05 > Recall - 2nd Row Center Seat Belt Loop Modification > Page 12325 In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 05037 > Jul > 05 > Recall - 2nd Row Center Seat Belt Loop Modification > Page 12326 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 05037 > Jul > 05 > Recall - 2nd Row Center Seat Belt Loop Modification > Page 12327 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > NHTSA05V163000 > Apr > 05 > Recall 05V163000: 2nd Row Seat Belt Modification Seat Belt: Recalls Recall 05V163000: 2nd Row Seat Belt Modification MAKE/MODELS: MODEL/BUILD YEARS: CADILLAC / ESCALADE 2003-2005 CHEVROLET / AVALANCHE 2003-2005 CHEVROLET / SILVERADO 2003-2005 CHEVROLET / SUBURBAN 2003-2005 CHEVROLET / TAHOE 2003-2005 GMC / SIERRA 2003-2005 GMC / YUKON 2003-2005 HUMMER / H2 2004-2005 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V163000 RECALL DATE: April 22, 2005 COMPONENT: Seat Belts: Rear POTENTIAL NUMBER OF UNITS AFFECTED: 1359824 SUMMARY: On certain crew cab pickup trucks and sport utility vehicles, the 2nd row center occupant seat belt routing may make it difficult to position the lap portion of the safety belt low around the hips of occupants, especially smaller occupants, seated in this position. Appropriate use of a child seat or booster seat, as recommended for small children, does improve the fit condition for this user group. In addition to instructions on proper infant and young child restraint (with child seats or boosters), special verbiage for restraining older child is included in the owner's manual text. CONSEQUENCE: A lap portion of the seat belt routing that is not low and snug on the hips can allow the lap belt to ride up on an occupant's abdomen instead of fitting low around their hipbones, and therefore, can expose them to more risk of abdominal and internal organ injury. REMEDY: Dealers will cut open the guide loop, remove a portion of the loop, and then the remaining two sides should be folded over and secured with a retainer. The manufacturer has not yet provided an owner notification schedule for this campaign. Owners should contact Cadillac at 1-866-982-2339, Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, or Hummer at 1-800-732-5493. NOTES: GM recall No. 05037. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 05037 > Jul > 05 > Recall - 2nd Row Center Seat Belt Loop Modification Technical Service Bulletin # 05037 Date: 050714 Recall - 2nd Row Center Seat Belt Loop Modification Second Row Center Safety Belt # 05037 - (Jul 14, 2005) Models: 2003-2005 CADILLAC ESCALADE, ESCALADE ESV, ESCALADE EXT 2003-2005 CHEVROLET AVALANCIE, SILVERADO CREW CAB, SUBURBAN, TAHOE 2003-2005 GMC SIERRA CREW CAB, YUKON, YUKON XL 2004-2005 HUMMER H2 Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado Crew Cab, Suburban, Tahoe; GMC Sierra Crew Cab, Yukon, Yukon XL; and 2004-2005 HUMMER H2 vehicles. On these vehicles, the seat loop in the second row center seating position may make it difficult to position the lap portion of the safety belt low around the hips of the occupant. In the event of a vehicle accident, if the lap portion of the safety belt routing is not low and snug on the hips, it may not properly restrain the occupant and could increase the risk of abdominal injury. Correction Dealers are to eliminate the seat loop by removing the safety belt from the loop and stitching the loop closed. Vehicles Involved Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 05037 > Jul > 05 > Recall - 2nd Row Center Seat Belt Loop Modification > Page 12337 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 05037 > Jul > 05 > Recall - 2nd Row Center Seat Belt Loop Modification > Page 12338 Involved are certain 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado Crew Cab, Suburban, Tahoe; GMC Sierra Crew Cab, Yukon, Yukon XL; and 2004-2005 HUMMER H2 vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US and Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (US) Recall Information, GMinfoNet (Canada) Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. For Export For dealers with involved vehicle, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers will not receive a report with the recall bulletin if they have no involved vehicles currently assigned. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 05037 > Jul > 05 > Recall - 2nd Row Center Seat Belt Loop Modification > Page 12339 Service Procedure 1. Note the position of the rear seats. 2. Position the seats to gain access to the lower seat belt anchor stud for the rear center seat. 3. Remove any cover necessary to gain access to the lower seat belt anchor point for the rear center seat. 4. Remove the nut (1) retaining the rear center seat's lower seat belt anchor (seat back shown in the up position). 5. Remove the belt anchor point from the stud. 6. Remove the belt from the seat loop on the front of the seat back cushion. 7. Route the belt outside of the seat loop and install it on the lower anchor stud. Be sure that the belt is not twisted. 8. Install the retaining nut to the anchor stud. Tighten Tighten the retaining nut to 53 Nm (39 lb ft). 9. Using an appropriate color of locally obtained upholstery thread and needle (size 16 recommended), sew the retaining loop closed in the center. 10. Reposition the seats to the customer's original position as noted in Step 1 Courtesy Transportation -- for US and Canada The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 05037 > Jul > 05 > Recall - 2nd Row Center Seat Belt Loop Modification > Page 12340 Policies and Procedures Manual for courtesy transportation guidelines. Claim Information Submit a Product Recall Claim with the information shown. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown this bulletin). Customer Notification -- For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility -- For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility -- All All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 05037 > Jul > 05 > Recall - 2nd Row Center Seat Belt Loop Modification > Page 12341 In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 05037 > Jul > 05 > Recall - 2nd Row Center Seat Belt Loop Modification > Page 12342 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 05037 > Jul > 05 > Recall - 2nd Row Center Seat Belt Loop Modification > Page 12343 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > NHTSA05V163000 > Apr > 05 > Recall 05V163000: 2nd Row Seat Belt Modification Seat Belt: All Technical Service Bulletins Recall 05V163000: 2nd Row Seat Belt Modification MAKE/MODELS: MODEL/BUILD YEARS: CADILLAC / ESCALADE 2003-2005 CHEVROLET / AVALANCHE 2003-2005 CHEVROLET / SILVERADO 2003-2005 CHEVROLET / SUBURBAN 2003-2005 CHEVROLET / TAHOE 2003-2005 GMC / SIERRA 2003-2005 GMC / YUKON 2003-2005 HUMMER / H2 2004-2005 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V163000 RECALL DATE: April 22, 2005 COMPONENT: Seat Belts: Rear POTENTIAL NUMBER OF UNITS AFFECTED: 1359824 SUMMARY: On certain crew cab pickup trucks and sport utility vehicles, the 2nd row center occupant seat belt routing may make it difficult to position the lap portion of the safety belt low around the hips of occupants, especially smaller occupants, seated in this position. Appropriate use of a child seat or booster seat, as recommended for small children, does improve the fit condition for this user group. In addition to instructions on proper infant and young child restraint (with child seats or boosters), special verbiage for restraining older child is included in the owner's manual text. CONSEQUENCE: A lap portion of the seat belt routing that is not low and snug on the hips can allow the lap belt to ride up on an occupant's abdomen instead of fitting low around their hipbones, and therefore, can expose them to more risk of abdominal and internal organ injury. REMEDY: Dealers will cut open the guide loop, remove a portion of the loop, and then the remaining two sides should be folded over and secured with a retainer. The manufacturer has not yet provided an owner notification schedule for this campaign. Owners should contact Cadillac at 1-866-982-2339, Chevrolet at 1-800-630-2438, GMC at 1-866-996-9463, or Hummer at 1-800-732-5493. NOTES: GM recall No. 05037. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Center Rear Seat Belt: Service and Repair Center Rear SEAT BELT REPLACEMENT - CENTER REAR CAUTION: To avoid personal injury to the occupants of the vehicle, observe the following precautions: - More than one supplier's seat belts are used, therefore, install ONLY the seat belt components specified in the GM parts catalog. - To verify that the correct seat belt components were installed, insert the seat belt latch in the seat belt buckle. The latch must be fully seated and be retained in the buckle until purposely released. REMOVAL PROCEDURE 1. Remove the seat belt guide cover (1). 2. Remove the rear seat armrest. 3. Release the J-Clip from under the center armrest. 4. Remove the nut from the seat belt retractor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Center Rear > Page 12350 5. Remove the bolt (1) from the seat belt anchor. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the bolt (1) to the seat belt anchor. Tighten Tighten the bolt to 52 N.m (38 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Center Rear > Page 12351 2. Install the nut to the seat belt retractor. Tighten Tighten the nut to 52 N.m (38 lb ft). 3. Install the J-Clip under the center armrest. 4. Install the rear seat armrest. 5. Install the seat belt guide cover (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Center Rear > Page 12352 Seat Belt: Service and Repair Center Front SEAT BELT REPLACEMENT - CENTER FRONT CAUTION: To avoid personal injury to the occupants of the vehicle, observe the following precautions: - More than one supplier's seat belts are used, therefore, install ONLY the seat belt components specified in the GM parts catalog. - To verify that the correct seat belt components were installed, insert the seat belt latch in the seat belt buckle. The latch must be fully seated and be retained in the buckle until purposely released. REMOVAL PROCEDURE 1. Remove the center front seat belt latch bolt. Remove the seat belt latch assembly from the vehicle. 2. Remove the center front seat belt buckle bolt. 3. Remove the buckle assembly from the seat. INSTALLATION PROCEDURE 1. Install the seat belt buckle assembly to the center front seat. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Center Rear > Page 12353 2. Install the seat belt buckle bolt. Tighten Tighten the bolt to 53 N.m (39 lb ft). 3. Install the seat belt latch assembly to the center front seat. 4. Install the seat belt latch bolt. Tighten Tighten the bolt to 53 N.m (39 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: Customer Interest Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 12362 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 12368 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seat Belt Buckle: Service and Repair Front SEAT BELT BUCKLE REPLACEMENT - FRONT CAUTION: To avoid personal injury to the occupants of the vehicle, observe the following precautions: - More than one supplier's seat belts are used, therefore, install ONLY the seat belt components specified in the GM parts catalog. - To verify that the correct seat belt components were installed, insert the seat belt latch in the seat belt buckle. The latch must be fully seated and be retained in the buckle until purposely released. REMOVAL PROCEDURE 1. Remove the front seat belt buckle nut (1). Disconnect the electrical connection (2). The right seat buckle is shown, the left is similar. 2. Remove the seat belt buckle from the vehicle. INSTALLATION PROCEDURE 1. Install the seat belt buckle in the vehicle. 2. Connect the electrical connection (2). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the front seat belt buckle nut (1). Tighten Tighten the nut to 53 N.m (39 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front > Page 12371 Seat Belt Buckle: Service and Repair Center Rear SEAT BELT BUCKLE REPLACEMENT - CENTER REAR CAUTION: To avoid personal injury to the occupants of the vehicle, observe the following precautions: - More than one supplier's seat belts are used, therefore, install ONLY the seat belt components specified in the GM parts catalog. - To verify that the correct seat belt components were installed, insert the seat belt latch in the seat belt buckle. The latch must be fully seated and be retained in the buckle until purposely released. REMOVAL PROCEDURE 1. Fold the rear seat to the open position. 2. Remove the two bolts that retain the buckle assembly to the back of the seat frame. 3. Remove the nut that retains the buckle assembly to the floor stud. 4. Remove the buckle assembly from the rear seat. INSTALLATION PROCEDURE 1. Install the buckle assembly to the rear seat. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the nut that retains the buckle assembly to the floor stud. Tighten Tighten the nut to 52 N.m (38 lb ft). 3. Install the two bolts that retain the buckle assembly to the back of the seat frame. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front > Page 12372 Tighten Tighten the bolts to 3 N.m (26 lb in). 4. Fold the rear seat to the closed position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front > Page 12373 Seat Belt Buckle: Service and Repair Seat Belt Buckle and Latch - Rear (Extended Cab) SEAT BELT BUCKLE AND LATCH REPLACEMENT - REAR (EXTENDED CAB) CAUTION: To avoid personal injury to the occupants of the vehicle, observe the following precautions: - More than one supplier's seat belts are used, therefore, install ONLY the seat belt components specified in the GM parts catalog. - To verify that the correct seat belt components were installed, insert the seat belt latch in the seat belt buckle. The latch must be fully seated and be retained in the buckle until purposely released. REMOVAL PROCEDURE 1. Pull the seat belt buckles through the rear seat cushion. Fold the rear seat up. 2. Remove the rear seat belt buckle nuts. 3. Remove the buckle assembly. INSTALLATION PROCEDURE 1. Position the buckle assembly to the floor panel stud. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear seat belt buckle nuts. Tighten Tighten the nuts to 53 N.m (39 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front > Page 12374 3. Fold the rear seat down. 4. Pull the seat belt buckles through the seat cushion. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front > Page 12375 Seat Belt Buckle: Service and Repair Seat Belt Buckle and Latch - Rear (Crew Cab) SEAT BELT BUCKLE AND LATCH REPLACEMENT - REAR (CREW CAB) REMOVAL PROCEDURE 1. Remove the rear seat cushion and cover. 2. Remove the bolt (13) that retains the buckle assembly (14) to the seat frame. 3. Remove the buckle assembly INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front > Page 12376 1. Install the buckle assembly. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolt (13) that retains the buckle assembly (14) to the seat frame. Tighten Tighten the bolts to 53 N.m (39 lb ft). 3. Install the rear seat cushion and cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams Seat Belt Buckle Switch: Diagrams Seat Belt Switch - Driver Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Page 12380 Seat Belt Switch - Front Passenger (With RPO Code AL0) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Technical Service Bulletins > Restraints - Extender Availability For Seat Belt Seat Belt Extension: Technical Service Bulletins Restraints - Extender Availability For Seat Belt INFORMATION Bulletin No.: 99-09-40-005F Date: June 23, 2010 Subject: Seat Belt Extender Availability Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2009‐2011 model years and update the Warranty Information. Please discard Corporate Bulletin Number 99-09-40-005E (Section 09 Restraints). Important: DO NOT use belt extenders when securing a child restraint. The seat and shoulder belt restraint systems used in all General Motors vehicles have sufficient belt length to accommodate most drivers and passengers. Consequently, requests for belt extensions (extenders) should be minimal. Seat belt extenders are available ONLY IN BLACK for most GM passenger cars and trucks produced in recent years. They are available in two different lengths, 23 cm (9 in) and 38 cm (15 in). They are designed to be coupled with the existing belts in each vehicle. When in use, the extender makes the belt arrangement a "custom fit" and use by anyone else or in another vehicle will lessen or nullify the protection offered by the vehicle's restraint system. For this reason, it is extremely important that the correct length extender be used for the vehicle and occupant intended. Important: Do not use an extender just to make it easier to buckle the safety belt. Use an extender only when you cannot buckle the safety belt without using an extender. Parts Information For part numbers, usage and availability of extenders, see Extension Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration catalog for the vehicle. U.S. Saab dealers should contact the Parts Help line. Canadian Saab dealers should fax requests to Partech Canada. Warranty Information ^ Seat belt extenders are a NO CHARGE item to all GM customers who request them for their specific vehicles. ^ Dealers should not be charging part costs since these extenders are supplied by GM to the dealers. ^ Dealers should not be charging labor costs since the extender can be customer installed. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Service and Repair > Seat Belt Buckle and Latch - Rear (Extended Cab) Seat Belt Latch: Service and Repair Seat Belt Buckle and Latch - Rear (Extended Cab) SEAT BELT BUCKLE AND LATCH REPLACEMENT - REAR (EXTENDED CAB) CAUTION: To avoid personal injury to the occupants of the vehicle, observe the following precautions: - More than one supplier's seat belts are used, therefore, install ONLY the seat belt components specified in the GM parts catalog. - To verify that the correct seat belt components were installed, insert the seat belt latch in the seat belt buckle. The latch must be fully seated and be retained in the buckle until purposely released. REMOVAL PROCEDURE 1. Pull the seat belt buckles through the rear seat cushion. Fold the rear seat up. 2. Remove the rear seat belt buckle nuts. 3. Remove the buckle assembly. INSTALLATION PROCEDURE 1. Position the buckle assembly to the floor panel stud. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear seat belt buckle nuts. Tighten Tighten the nuts to 53 N.m (39 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Service and Repair > Seat Belt Buckle and Latch - Rear (Extended Cab) > Page 12389 3. Fold the rear seat down. 4. Pull the seat belt buckles through the seat cushion. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Service and Repair > Seat Belt Buckle and Latch - Rear (Extended Cab) > Page 12390 Seat Belt Latch: Service and Repair Seat Belt Buckle and Latch - Rear (Crew Cab) SEAT BELT BUCKLE AND LATCH REPLACEMENT - REAR (CREW CAB) REMOVAL PROCEDURE 1. Remove the rear seat cushion and cover. 2. Remove the bolt (13) that retains the buckle assembly (14) to the seat frame. 3. Remove the buckle assembly INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Service and Repair > Seat Belt Buckle and Latch - Rear (Extended Cab) > Page 12391 1. Install the buckle assembly. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolt (13) that retains the buckle assembly (14) to the seat frame. Tighten Tighten the bolts to 53 N.m (39 lb ft). 3. Install the rear seat cushion and cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation FASTEN SAFETY BELT INDICATOR The fasten safety belt indicator may only be illuminated during RUN. The instrument panel cluster (IPC) illuminates the fasten safety belt indicator under the following conditions: - During bulb check. - The inflatable restraint sensing and diagnostic module (SDM) sends the status of the driver's seat belt switch to the IPC via a class 2 message. If the driver's seat belt is unfastened, the IPC will illuminate the fasten safety belt indicator for 72 seconds or until the driver's seat belt is fastened. If the driver's seat belt is unfastened within 8 seconds following the bulb check, the IPC will send a class 2 serial message requesting 5 chimes to sound. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Testing and Inspection Seat Belt Retractor: Testing and Inspection EMERGENCY LOCKING RETRACTORS CAUTION: Perform this test in an area clear of other vehicles or obstructions. Do not conduct this test on the open road. A large, empty parking lot is suitable. Failure to observe this precaution may result in damage to the vehicle and possible personal injury. 1. Fasten the seat belts, an assistant is needed when the retractor under test is not part of the driver seat belt. 2. Accelerate the vehicle slowly to 16 km/h (10 mph) and apply the brakes firmly. 3. Verify that the seat belt locks when braking firmly. 4. If the belt does not lock, proceed with the following steps. 4.1. Remove the seat belt retractor assembly. 4.2. Tilt the seat belt retractor slowly. 4.3. Ensure that the seat belt webbing can be pulled from the retractor at an inclination of 15 degrees or less and cannot be pulled from the retractor at an inclination of 60 degrees or more. 4.4. If the seat belt retractor does not operate as described, replace the retractor assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front Seat Belt Retractor: Service and Repair Left Front SEAT BELT RETRACTOR REPLACEMENT - LEFT FRONT CAUTION: To avoid personal injury to the occupants of the vehicle, observe the following precautions: - More than one supplier's seat belts are used, therefore, install ONLY the seat belt components specified in the GM parts catalog. - To verify that the correct seat belt components were installed, insert the seat belt latch in the seat belt buckle. The latch must be fully seated and be retained in the buckle until purposely released. REMOVAL PROCEDURE 1. Move the front seat to the full forward position. IMPORTANT: Do not remove the seat back cover from the head restraint retainers. 2. Remove the seat back cover and pad. 3. Separate the seat foam from the cardboard to gain access to the retainer on the seat belt side. 4. Remove the seat belt side cardboard retainers. 5. Move the cardboard outwards to gain access to the lower seat belt retractor bolt. 6. Remove the retractor bolt. 7. Remove the retractor tower retaining screw. 8. Remove the retractor tower cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 12400 9. Remove the upper anchor bolt. 10. Remove the retractor from the seat. INSTALLATION PROCEDURE 1. Position the seat belt retractor onto the seat. Line up the tab on the retractor to the tab on the seat frame. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the upper anchor bolt. Tighten Tighten the bolt to 53 N.m (39 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 12401 3. Install the retractor tower cover. 4. Install the retractor tower cover retaining screw. Tighten Tighten the screw to 2 N.m (18 lb in). 5. Install the retractor. 6. Install the retractor bolt. Tighten Tighten the bolt to 53 N.m (39 lb ft). 7. Install the rear cardboard panel retainers. 8. Install the seat back cover and pad. 9. Move the seat to its original position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 12402 Seat Belt Retractor: Service and Repair Right Front SEAT BELT RETRACTOR REPLACEMENT - RIGHT FRONT CAUTION: To avoid personal injury to the occupants of the vehicle, observe the following precautions: - More than one supplier's seat belts are used, therefore, install ONLY the seat belt components specified in the GM parts catalog. - To verify that the correct seat belt components were installed, insert the seat belt latch in the seat belt buckle. The latch must be fully seated and be retained in the buckle until purposely released. REMOVAL PROCEDURE 1. Move the front seat to the full forward position. IMPORTANT: Do not remove the seat back cover from the head restraint retainers. 2. Remove the seat back cover and pad. 3. Separate the seat foam from the cardboard to gain access to the retainer on the seat belt side. 4. Remove the seat belt side cardboard retainers. 5. Move the cardboard outwards to gain access to the lower seat belt retractor bolt. 6. Remove the retractor bolt. 7. Remove the retractor tower retaining screw. 8. Remove the retractor tower cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 12403 9. Remove the upper anchor bolt. 10. Remove the retractor from the seat. INSTALLATION PROCEDURE 1. Position the seat belt retractor onto the seat. Line up the tab on the retractor to the tab on the seat frame. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the upper anchor bolt. Tighten Tighten the bolt to 53 N.m (39 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 12404 3. Install the retractor tower cover. 4. Install the retractor tower cover retaining screw. Tighten Tighten the screw to 2 N.m (18 lb in). 5. Install the retractor. 6. Install the retractor bolt. Tighten Tighten the bolt to 53 N.m (39 lb ft). 7. Install the rear cardboard panel retainers. 8. Install the seat back cover and pad. 9. Move the seat to its original position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 12405 Seat Belt Retractor: Service and Repair Rear (Extended Cab) SEAT BELT RETRACTOR REPLACEMENT - REAR (EXTENDED CAB) CAUTION: To avoid personal injury to the occupants of the vehicle, observe the following precautions: - More than one supplier's seat belts are used, therefore, install ONLY the seat belt components specified in the GM parts catalog. - To verify that the correct seat belt components were installed, insert the seat belt latch in the seat belt buckle. The latch must be fully seated and be retained in the buckle until purposely released. REMOVAL PROCEDURE 1. Remove the rear seat. 2. Remove the seat belt guide cover (1). 3. Remove the rear seat belt to body bolts (2). 4. Remove the rear quarter trim panel. 5. Remove the rear seat belt retractor to body bolt (1). 6. Remove the retractor from the vehicle. INSTALLATION PROCEDURE 1. Install the retractor to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 12406 2. Install the rear seat belt retractor to body bolt (1). Tighten Tighten the bolt to 53 N.m (39 lb ft). 3. Install the rear quarter trim panel. 4. Install the rear seat belt to body bolts (2). Tighten Tighten the bolts to 53 N.m (39 lb ft). 5. Install the seat belt guide cover (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 12407 6. Install the rear seat. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 12408 Seat Belt Retractor: Service and Repair Rear (Crew Cab) SEAT BELT RETRACTOR REPLACEMENT - REAR (CREW CAB) CAUTION: To avoid personal injury to the occupants of the vehicle, observe the following precautions: - More than one supplier's seat belts are used, therefore, install ONLY the seat belt components specified in the GM parts catalog. - To verify that the correct seat belt components were installed, insert the seat belt latch in the seat belt buckle. The latch must be fully seated and be retained in the buckle until purposely released. REMOVAL PROCEDURE 1. Remove the rear seat, if required. 2. Remove the rear quarter trim panel. 3. Remove the rear seat belt to body bolts. 4. Remove the rear seat belt retractor to body bolt (1). 5. Remove the retractor from the vehicle. INSTALLATION PROCEDURE 1. Install the retractor to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear seat belt retractor to body bolt (1). Tighten Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 12409 Tighten the bolt to 53 N.m (39 lb ft). 3. Install the rear seat belt to body bolts. Tighten Tighten the bolts to 53 N.m (39 lb ft). 4. Install the rear quarter trim panel. 5. Install the rear seat, if removed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations Passenger Presence Components - Under Front Passenger Seat Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Page 12413 Seat Sensor/Switch: Diagrams Inflatable Restraint Seat Position Switch - Left (With RPO Code AL0) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Page 12414 Inflatable Restraint Seat Position Switch - Right ((With RPO Code AL0) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Page 12415 Seat Sensor/Switch: Service and Repair INFLATABLE RESTRAINT SEAT POSITION SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the passenger or driver's seat from the vehicle. 2. Disconnect the electrical connector from the seat position sensor. CAUTION: Eye protection must be worn when drilling rivets to reduce the chance of personal injury. 3. Drill out the rivets that retain the seat position sensor (1) to the seat adjuster track bracket. 4. Remove the seat position sensor from the seat adjuster track bracket. INSTALLATION PROCEDURE 1. Install the seat position sensor to the seat adjuster bracket. 2. Install the rivets that retain the seat position sensor (1) to the seat adjuster track bracket. 3. Connect the electrical connector to the seat position sensor. 4. Install the passenger or driver's seat to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations Center of the I/P - Accessory Switches Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 12420 Inflatable Restraint I/P Module Disable Switch (With RPO Code C99) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Inflatable Restraint I/P Module Disable Switch (HD Model) Air Bag Deactivation Switch: Description and Operation Inflatable Restraint I/P Module Disable Switch (HD Model) INFLATABLE RESTRAINT I/P MODULE DISABLE SWITCH (HD MODEL PICKUPS) The instrument panel (I/P) module disable switch is a manual 2-position key switch. The I/P module disable switch allows the vehicle operator the ability to enable or disable the I/P module (passenger frontal air bag). The I/P module disable switch interfaces with the inflatable restraint sensing and diagnostic module (SDM) to request the enabling or disabling of the I/P module. The occupants are notified of the enabling or disabling of the I/P module via the I/P module disable switch ON/OFF indicators located on the I/P module disable switch. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Inflatable Restraint I/P Module Disable Switch (HD Model) > Page 12423 Air Bag Deactivation Switch: Description and Operation Inflatable Restraint I/P Module Disable Switch INFLATABLE RESTRAINT I/P MODULE DISABLE SWITCH The instrument panel (I/P) module disable switch is a manual 2-position key switch. The I/P module disable switch allows the vehicle operator the ability to enable or disable the I/P module (passenger frontal air bag). The I/P module disable switch interfaces with the passenger presence system (PPS) module to request the enabling or disabling of the I/P module. The occupants are notified of the enabling or disabling of the I/P module via the I/P module disable switch ON/OFF indicator and the PASSENGER AIR BAG ON/OFF indicators located on the rear view mirror. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Page 12424 Air Bag Deactivation Switch: Service and Repair INFLATABLE RESTRAINT INSTRUMENT PANEL (I/P) MODULE DISABLE SWITCH REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Service Precautions. 1. Remove the instrument panel trim bezel. 2. Remove the I/P module switch from the lower right opening of the switch plate panel. 3. Disconnect the I/P module switch electrical connector. INSTALLATION PROCEDURE 1. Connect the I/P module switch electrical connector. 2. Install the I/P module switch into the lower right opening of the switch plate panel. 3. Install the instrument panel trim bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations Front End Sensors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 12428 Right Side Impact Sensor (With RPO Code HP2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 12429 Impact Sensor: Diagrams Inflatable Restraint Front End Sensor - Left Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 12430 Inflatable Restraint Front End Sensor - Right Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 12431 Inflatable Restraint Front End Sensor (With RPO Code HVY) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 12432 Inflatable Restraint Side Impact Sensor (SIS) - Right (With RPO Code HP2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Front End Sensors Impact Sensor: Description and Operation Front End Sensors INFLATABLE RESTRAINT FRONT END SENSORS The front end sensors are equipped on vehicles to supplement the SIR system performance. The front end sensors are electronic and are not part of the deployment loops, but instead provide inputs to the sensing and diagnostic module (SDM). The front end sensors can assist in determining the severity of some frontal collisions. The SDM uses the input from the front end sensors to assist in determining the severity of a frontal collision further supporting air bag deployment. If the SDM determines a deployment is warranted, the SDM will cause current to flow through the deployment loops deploying the frontal air bags. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Front End Sensors > Page 12435 Impact Sensor: Description and Operation Side Impact Sensor (SIS) (Right) With RPO HP2 INFLATABLE RESTRAINT SIDE IMPACT SENSOR (SIS) (RIGHT) WITH RPO HP2 The right side impact sensor (SIS) contains a sensing device which monitors vehicle acceleration and velocity changes to detect side collisions that are severe enough to warrant disabling the 42-volt system. The SIS is not part of the deployment loop, but instead provides an input to the sensing and diagnostic module (SDM). When the SDM receives a signal from the SIS that a collision has occurred, the SDM communicates this over the vehicles communication bus. The module responsible for the 42-volt system receives this message and disables the 42-volt system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Sensor: Service and Repair Front INFLATABLE RESTRAINT FRONT END SENSOR REPLACEMENT REMOVAL PROCEDURE CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1. 2. Disconnect the electrical connector. 3. Remove the connector position assurance (CPA) from the connector. 4. Remove the sensor bolt. 5. Remove the sensor (2) from the vehicle. INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other contaminants from the mounting surface (1). IMPORTANT: Refer to SIR Service Precautions. 2. Point the arrow on the sensor toward the front of the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the sensor (2) horizontally to the radiator support. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 12438 Tighten Tighten the bolt to 9 N.m (79 lb in). 4. Connect the electrical connector to the sensor (2). 5. Install the CPA. 6. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 12439 Impact Sensor: Service and Repair Side INFLATABLE RESTRAINT SIDE IMPACT SENSOR REPLACEMENT REMOVAL PROCEDURE CAUTION: - Refer to SIR Inflator Module Handling and Storage Caution in Service Precautions. - When carrying an undeployed inflatable restraint seat belt pretensioner: - Do not carry the seat belt pretensioner by the wires or connector. - Carry the seat belt pretensioner by the piston tube, keeping hands and fingers away from the cable. - Make sure the open end of the seat belt pretensioner piston tube points away from you and other people. - Do not cover the seat belt pretensioner piston tube opening with your hand. Failure to observe these guidelines may result in personal injury. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 6. 2. Remove the front door trim panel. 3. Loosen the 2 inflatable restraint side impact sensor fasteners (2). 4. Remove the inflatable restraint side impact sensor (1) from the door (4). 5. Remove the connector position assurance (CPA) (3), and disconnect the inflatable restraint side impact sensor yellow 2-way harness connector (5). INSTALLATION PROCEDURE 1. Connect the inflatable restraint side impact sensor yellow 2-way harness connector (5) to the inflatable restraint side impact sensor (1). 2. Install the CPA (3) to the inflatable restraint side impact sensor yellow 2-way connector (5). 3. Install the inflatable restraint side impact sensor (1) to the door (4). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 12440 NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the fasteners (2) to the inflatable restraint side impact sensor (1) using only hand tools. Tighten Tighten the fasteners to 10 N.m (89 lb in). 5. Install the door trim panel. 6. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 6. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 12441 Impact Sensor: Service and Repair Sensor Replacement Guidelines SENSOR REPLACEMENT GUIDELINES The SIR sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. For example, a moderate collision where the front of the vehicle impacts a tree. If the vehicle has an SIR sensor mounted forward of the radiator, it must be replaced. - Replace the sensor whether or not the air bags have deployed. - Replace the sensor even if it appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR sensing system. Do not try to determine whether the sensor is undamaged, replace the sensor. Also, if you follow a Diagnostic Trouble Code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams Seat Belt Buckle Switch: Diagrams Seat Belt Switch - Driver Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Page 12445 Seat Belt Switch - Front Passenger (With RPO Code AL0) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set Seat Occupant Sensor: Customer Interest SRS - Air Bag Lamp ON/DTC B0092 Set Bulletin No.: 02-09-41-002A Date: March 24, 2004 TECHNICAL Subject: Air Bag Lamp On, Passenger Air Bag Indicator Always Reads OFF, DTC B0092 Set (Repair Passenger Presence System (PPS) Sensor Harness) Models: 2003-2004 Cadillac Escalade, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon XL with Sensor Indicator Inflatable Restraint Front Passenger/Child Presence Detector (RPO ALO) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 02-09-41-002 (Section 09 - Restraints). Condition Some customers may comment that the Air Bag Lamp is on and the Passenger Air Bag indicator always reads OFF. Upon investigation, the technician may find DTC B0092 set. Cause The cause of this condition may be a shorted Passenger Presence System (PPS) sensor wire. The PPS sensor harness is located under the front passenger seat. This harness may be pinched between the seat frame and the track/riser. Correction Locate the PPS sensor (1) and inspect the harness for proper routing. If the harness is pinched between the seat frame and the track/riser, use the procedure listed below to repair wire(s). 1. Move the front passenger seat to the full rearward and full tilt up position. 2. Loosen the seat frame to track/riser nut and remove the harness. 3. Tighten the seat frame to track/riser nut. 4. Repair any damaged wires. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set > Page 12454 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 06-08-50-009F > Dec > 10 > Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set Seat Occupant Sensor: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC B0092 Set Bulletin No.: 02-09-41-002A Date: March 24, 2004 TECHNICAL Subject: Air Bag Lamp On, Passenger Air Bag Indicator Always Reads OFF, DTC B0092 Set (Repair Passenger Presence System (PPS) Sensor Harness) Models: 2003-2004 Cadillac Escalade, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon XL with Sensor Indicator Inflatable Restraint Front Passenger/Child Presence Detector (RPO ALO) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 02-09-41-002 (Section 09 - Restraints). Condition Some customers may comment that the Air Bag Lamp is on and the Passenger Air Bag indicator always reads OFF. Upon investigation, the technician may find DTC B0092 set. Cause The cause of this condition may be a shorted Passenger Presence System (PPS) sensor wire. The PPS sensor harness is located under the front passenger seat. This harness may be pinched between the seat frame and the track/riser. Correction Locate the PPS sensor (1) and inspect the harness for proper routing. If the harness is pinched between the seat frame and the track/riser, use the procedure listed below to repair wire(s). 1. Move the front passenger seat to the full rearward and full tilt up position. 2. Loosen the seat frame to track/riser nut and remove the harness. 3. Tighten the seat frame to track/riser nut. 4. Repair any damaged wires. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Occupant Sensor: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set > Page 12464 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Occupant Sensor: > 06-08-50-009F > Dec > 10 > Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations Passenger Presence Components - Under Front Passenger Seat Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 12473 Seat Sensor/Switch: Diagrams Inflatable Restraint Seat Position Switch - Left (With RPO Code AL0) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 12474 Inflatable Restraint Seat Position Switch - Right ((With RPO Code AL0) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 12475 Seat Sensor/Switch: Service and Repair INFLATABLE RESTRAINT SEAT POSITION SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the passenger or driver's seat from the vehicle. 2. Disconnect the electrical connector from the seat position sensor. CAUTION: Eye protection must be worn when drilling rivets to reduce the chance of personal injury. 3. Drill out the rivets that retain the seat position sensor (1) to the seat adjuster track bracket. 4. Remove the seat position sensor from the seat adjuster track bracket. INSTALLATION PROCEDURE 1. Install the seat position sensor to the seat adjuster bracket. 2. Install the rivets that retain the seat position sensor (1) to the seat adjuster track bracket. 3. Connect the electrical connector to the seat position sensor. 4. Install the passenger or driver's seat to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Description and Operation Accessory Delay Module: Description and Operation RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION SERIAL DATA CONTROL OF RETAINED ACCESSORY POWER (RAP) The class 2 modules receive the power mode message from the body control module (BCM) over the serial data circuits, indicating when the RAP power mode is current. The BCM monitors the ignition switch position, battery condition and passenger compartment doors status to determine whether RAP should be initiated. The modules then support the operation of the systems under their control as required by their RAP power mode operation. RAP will end when one of the following conditions is met: The BCM receives an input indicating the opening of any compartment door. - The BCM internal timer for the RAP expires after approximately 10 minutes. - The BCM detects a decrease in battery capacity below a prescribed limit. The BCM then sends a serial data power mode message Off-Awake ending the RAP function. The class 2 RAP functions are: The power windows - The radio Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accessory Delay Module: Initial Inspection and Diagnostic Overview Diagnostic Starting Point DIAGNOSTIC STARTING POINT Begin the system diagnosis with the Diagnostic System Check - Accessory Delay Module. The diagnostic system check will provide the following information: - The identification of the control modules which command the system - The ability of the control modules to communicate through the serial data circuit - The identification of any stored diagnostic trouble codes DTCs and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check DIAGNOSTIC SYSTEM CHECK TEST DESCRIPTION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12482 Steps 1-5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12483 Steps 6-7 The numbers below refer to the step numbers on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 3. This step tests for valid system power moding in all ignition switch positions. 5. The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12484 Accessory Delay Module: Symptom Related Diagnostic Procedures A Symptoms SYMPTOMS IMPORTANT: Review the system operation in order to familiarize yourself with the system functions. Refer to Retained Accessory Power (RAP) Description and Operation. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the RAP feature. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Retained Accessory Power (RAP) On After Timeout - Retained Accessory Power (RAP) Inoperative Steps 1-3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12485 Steps 4-5 Steps 1-5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12486 Accessory Delay Module: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Courtesy Lamp Switch: Input showing state of the courtesy lamp as commanded by the BCM. Cargo Door Ajar Switch: Input from the liftgate and liftglass indicating their status. Driver Door Ajar Switch (w/o DDM): Input from the driver door indicating door status. Left Rear/Rear Cargo Door Ajar Switch: Input from the left rear door indicating its status. Passenger Door Ajar Switch (w/o PDM): Input from the front passenger door indicating door status. RAP Relay: Output indicates the RAP Relay state that the control module has commanded. Right Rear Door Ajar Sw.: Input from the right rear door indicating door status. BCM Data List DDM Data List PDM Data List Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-46-003B > Feb > 05 > Instruments - GPS System Performance Degradation Antenna, Navigation: Customer Interest Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts > Page 12501 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-003B > Feb > 05 > Instruments - GPS System Performance Degradation Antenna, Navigation: All Technical Service Bulletins Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts > Page 12511 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > Page 12512 Antenna, Navigation: Description and Operation CELLULAR AND NAVIGATION ANTENNAS This vehicle will be equipped with either separate cellular and navigation antennas, or a combination cellular and navigation antenna, which brings the functions of both into a single part. The cellular antenna is the component that allows the Onstar(R) system to send and receive data over airwaves by means of cellular technology. This antenna is connected at the base to a coax cable that plugs directly into the vehicle communication interface module (VCIM). The navigation antenna is used to collect the constant signals of the orbiting satellites. Within the antenna, is housed a low noise amplifier that allows for a more broad and precise reception of this data. The current global positioning system (GPS) location is collected by the module every time a keypress is made. The Onstar(R) Call Center also has the capability of pinging the vehicle during an Onstar(R) call, which commands the module to retrieve the latest GPS location and transmit it to the Onstar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged. In the event the VCP loses, or is removed from power, this history location is used by the Onstar(R) Call Center as a default. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. This antenna requires a clear and unobstructed path to the satellites in the sky. Window tinting on vehicles may interfere with the GPS sensor functions, depending upon the amount of darkening and/or metallic particles that are embedded in the film of the tinting material. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > Page 12513 Antenna, Navigation: Service and Repair ANTENNA ASSEMBLY REPLACEMENT - CELLULAR AND NAVIGATION REMOVAL PROCEDURE 1. Lower the headliner. Refer to Headliner Replacement in Interior Trim 2. Disconnect the cables from the antenna. 3. Loosen the retaining nut until the antenna assembly can be pulled from the top of the roof. INSTALLATION PROCEDURE 1. Place the antenna assembly on the roof opening. NOTE: Refer to Fastener Notice in Service Precautions. 2. Tighten the retaining nut. Tighten Tighten the nut to 6 N.m (53 lb in). 3. Connect the antenna cables. 4. Install the headliner. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Phone: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 12518 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 12523 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Service and Repair > Coaxial Cable - Navigation and Cellular Telephone Antenna Global Positioning System Antenna: Service and Repair Coaxial Cable - Navigation and Cellular Telephone Antenna COAXIAL CABLE REPLACEMENT - NAVIGATION AND CELLULAR TELEPHONE ANTENNA REMOVAL PROCEDURE 1. Remove the I/P trim panel. 2. Lower the headliner. 3. Disconnect the cables from the antenna base. IMPORTANT: Observe the routing of the cables. 4. Remove the cable retainers from the roof and pillar. 5. Disconnect the cable (3) from the module. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Service and Repair > Coaxial Cable - Navigation and Cellular Telephone Antenna > Page 12526 1. Install the cable retainers to the roof and pillar. 2. Connect the cables (3) to the module. 3. Connect the cables to the antenna base. IMPORTANT: Ensure the cables are routed properly and there is no sharp bends in the cables. 4. Install the headliner. 5. Install the I/P trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Service and Repair > Coaxial Cable - Navigation and Cellular Telephone Antenna > Page 12527 Global Positioning System Antenna: Service and Repair Antenna Assembly Replacement - Cellular and Navigation ANTENNA ASSEMBLY REPLACEMENT - CELLULAR AND NAVIGATION REMOVAL PROCEDURE 1. Lower the headliner. Refer to Headliner Replacement in Interior Trim 2. Disconnect the cables from the antenna. 3. Loosen the retaining nut until the antenna assembly can be pulled from the top of the roof. INSTALLATION PROCEDURE 1. Place the antenna assembly on the roof opening. NOTE: Refer to Fastener Notice in Service Precautions. 2. Tighten the retaining nut. Tighten Tighten the nut to 6 N.m (53 lb in). 3. Connect the antenna cables. 4. Install the headliner. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Extension Cable Replacement Antenna Cable: Service and Repair Antenna Extension Cable Replacement ANTENNA EXTENSION CABLE REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel trim panel. 2. Disconnect the extension cable from the radio. 3. Disconnect the extension cable from the HVAC duct. 4. Disconnect the extension cable from the antenna. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Extension Cable Replacement > Page 12533 INSTALLATION PROCEDURE 1. Connect the extension cable to the radio. 2. Connect the extension cable to the HVAC duct. 3. Connect the extension cable to the antenna. 4. Install the instrument panel trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Extension Cable Replacement > Page 12534 Antenna Cable: Service and Repair Coaxial Cable Replacement - Digital Radio (Primary) COAXIAL CABLE REPLACEMENT - DIGITAL RADIO (PRIMARY) REMOVAL PROCEDURE 1. Remove the windshield pillar garnish molding. 2. Disconnect the XM radio antenna cable (1). NOTE: Use care when removing or installing the headliner. Excessive bending will damage the headliner. 3. Lower the front of the headliner. 4. Disconnect the XM antenna cable from the antenna connection above the headliner. 5. Remove the cable clips from the windshield pillar and remove the antenna cable from the vehicle. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Extension Cable Replacement > Page 12535 1. Install the XM antenna cable and clips to the windshield pillar. 2. Connect the cable to the antenna connection above the headliner. 3. Install the headliner. 4. Connect the XM radio antenna cable (1) at the IP. 5. Install the windshield pillar garnish molding. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Extension Cable Replacement > Page 12536 Antenna Cable: Service and Repair Coaxial Cable Replacement - Digital Radio (Extension) COAXIAL CABLE REPLACEMENT - DIGITAL RADIO (EXTENSION) REMOVAL PROCEDURE 1. Remove the upper trim panel from the instrument panel (I/P). 2. Disconnect the digital radio antenna cable (1). 3. Fully open the I/P storage compartment in order to access the digital receiver (3). 4. Disconnect the antenna cable (2) from the digital receiver (3). 5. Disengage the antenna cable clips (4, 6) from the I/P. 6. Remove the digital radio antenna extension cable (5). INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Extension Cable Replacement > Page 12537 1. Install the digital radio extension cable (5) to the I/P. 2. Engage the antenna cable clips (4, 6) to the I/P. 3. Connect the antenna cable (2) to the digital receiver (3). 4. Connect the digital radio antenna extension cable to the digital radio antenna cable (1). 5. Install the I/P upper trim panel. 6. Close the I/P storage compartment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Ignition Key In Signal, Antitheft > Component Information > Locations Steering Wheel and Column Sub-System Components Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 04-08-52-005 > Jun > 04 > Keyless Entry - Inoperative Keyless Entry Module: Customer Interest Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 04-08-52-005 > Jun > 04 > Keyless Entry - Inoperative > Page 12551 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 04-08-52-005 > Jun > 04 > Keyless Entry - Inoperative Keyless Entry Module: All Technical Service Bulletins Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 04-08-52-005 > Jun > 04 > Keyless Entry - Inoperative > Page 12557 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Description and Operation Keyless Entry Receiver: Description and Operation REMOTE CONTROL DOOR LOCK RECEIVER MODULE SYSTEM The remote control door lock receiver module system may also arm and disarm the CTD system. When the remote control door lock receiver receives a door lock or an unlock signal from the key fob, the remote control door lock receiver sends a message to the BCM. The message orders the BCM to perform the appropriate door lock/unlock command. The BCM detects the message and performs one of the following functions: - Locks the doors and enters the armed initiated mode - Unlocks the doors and enters the ready-to-arm mode Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Description and Operation > Page 12561 Keyless Entry Receiver: Service and Repair REMOTE CONTROL DOOR LOCK RECEIVER REPLACEMENT The remote control door lock module is incorporated into the passenger side window switch module. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair TRANSMITTER BATTERY REPLACEMENT REMOVAL PROCEDURE Under normal use, the battery in the transmitter will last about 2 years. For battery replacement, use a Panasonic(R) 3 volt, type CR2032, or equivalent. 1. Open the transmitter case and perform the following steps: 1.1. Insert a dime between the 2 halves of the transmitter near the key ring hole. 1.2. Twist the dime. 2. Remove the battery. INSTALLATION PROCEDURE 1. Install the battery with the (+) positive side down. 2. Close the transmitter case and perform the following steps: 2.1. Align the top and bottom covers. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair > Page 12566 2.2. Press together the top and the bottom covers. 2.3. Inspect the operation of the transmitter. 3. Synchronize the transmitter. Refer to Transmitter Synchronization. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations > Page 12570 Passlock Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations > Page 12571 Lock Cylinder Switch: Description and Operation PASSLOCK(TM) SENSOR The Passlock(TM) sensor is inside the ignition cylinder lock housing. The Passlock(TM) sensor contains 2 hall effect sensors. The tamper hall effect sensor is on the top. The security hall effect sensor is under the tamper hall effect sensor. Both of the hall effect sensors monitor the magnet of the lock cylinder through an opening. The tamper hall effect sensor is physically placed on top of the security hall effect sensor. This arrangement enables the tamper hall effect sensor to engage first if an intruder attempts to bypass the Passlock(TM) sensor by placing a large magnet around that area of the steering column. There is a tamper resistor inside the Passlock(TM) sensor in order to help prevent tamper to the system. Passlock(TM) equipped vehicles have a selection of 10 different security resistors ranging from 0.5K ohms up to 13.6K ohms. Installing one of the security resistors inside the Passlock(TM) sensor will generate a unique Passlock(TM) code. All 10 combinations of the Passlock(TM) sensor have the same part number. However, you cannot simply replace the Passlock(TM) sensor and expect the system to operate properly. Always start by performing the Diagnostic System Check first and following the instructions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Diagrams Cellular Microphone Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Diagrams > Page 12576 Cellular Phone Microphone: Description and Operation ONSTAR(R) MICROPHONE The Onstar(R), or cellular microphone can be part of the rearview mirror assembly, or on some vehicle lines, can be a separate, stand alone unit. In either case, the microphone is supplied voltage on the cellular microphone signal circuit, while voice data from the user is sent back to the vehicle communication interface module (VCIM) by means of either a cellular microphone low reference circuit or a drain wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Diagrams > Page 12577 Cellular Phone Microphone: Service and Repair MICROPHONE REPLACEMENT - RADIO VOLUME COMPENSATOR INTERIOR REMOVAL PROCEDURE 1. Remove the floor console bezel. 2. Remove the floor console cupholder. 3. Remove the floor console storage bin. 4. Remove the floor console end panel. 5. Move the drivers seat fully forward. 6. Reposition the inboard seat track trim (1) in order to gain access to the rear console side panel screw (2). 7. Remove the rear console side panel screw. 8. Move the drivers seat to the fully rearward. 9. Remove the front console side panel screw (1). IMPORTANT: The floor console drivers side trim panel can not be removed until the noise compensation microphone electrical connector hold down clip is released from the console. 10. Carefully pull outward on the trim panel to release the trim panel clips. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Diagrams > Page 12578 11. Release the microphone electrical connector clip from the console. 12. Disconnect the radio volume compensator microphone (2) electrical connector. 13. Remove the screws (1) that retaining the radio volume compensator microphone (2) to the floor console trim panel. 14. Remove the radio volume compensator microphone (2) from the floor console side trim panel. INSTALLATION PROCEDURE 1. Install the radio volume compensator microphone (2) to the floor console side trim panel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the radio volume compensator microphone screws (1). Tighten Tighten the screws to 2 N.m (18 lb in). 3. Align the side trim panel to the floor console and connect the radio volume compensator microphone (2) electrical connector. 4. Install the electrical connector hold down clip to the floor console. 5. Align the trim panel to the floor console, push the panel towards the floor console to engage the panel clips. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Diagrams > Page 12579 6. Install the front console side panel screw (1). Tighten Tighten the screws to 2 N.m (18 lb in). 7. Move the front seat fully forward. 8. Install the rear console side panel screw (2). Tighten Tighten the retaining screw to 2 N.m (18 lb in). 9. Reposition the inboard seat track trim (1). 10. Install the floor console storage bin. 11. Install the floor console end panel. 12. Install the floor console cupholder. 13. Install the floor console bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 12588 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 12589 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 12590 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Component Information > Locations Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 05-08-50-008 > Aug > 05 > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 05-08-50-008 > Aug > 05 > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 12602 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 05-08-50-008 > Aug > 05 > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 12603 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 05-08-50-008 > Aug > 05 > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 12604 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 05-08-05-008 > Aug > 05 > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 05-08-05-008 > Aug > 05 > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 12615 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 05-08-05-008 > Aug > 05 > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 12616 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 05-08-05-008 > Aug > 05 > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 12617 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 05-08-05-008 > Aug > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 05-08-05-008 > Aug > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 12623 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 05-08-05-008 > Aug > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 12624 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 05-08-05-008 > Aug > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 12625 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Instruments - DIC Perceived Fuel Economy Settings Driver/Vehicle Information Display: Technical Service Bulletins Instruments - DIC Perceived Fuel Economy Settings Bulletin No.: 03-00-89-021 Date: July 30, 2003 INFORMATION Subject: New Vehicle Pre-Delivery Inspection - Perceived Fuel Economy and Driver Information Center (DIC) Settings Models: 2003-2004 Passenger Cars and Trucks 2003-2004 HUMMER H2 with Driver Information Center (DIC) The customer's initial perception of vehicle fuel economy, based upon the information displayed on the Driver Information Center (DIC), may contribute to poor ratings for fuel economy in various automotive surveys. The way the vehicle is handled during the build and shipping process may leave inaccurate values in the history of the DIC. During the pre-delivery inspection, the dealership must reset the "average fuel economy" setting. Reset the average fuel economy setting according to the information in the appropriate Owner's Manual. Once reset, the average fuel economy will then be calculated starting from that point. The data used to determine fuel range is an average of recent driving conditions. This setting cannot be reset. However, as the customer's driving conditions change, the data will be gradually updated to reflect more accurate readings. If a customer inquires about fuel economy, and the fuel consumption information is not on the price sticker, do not exaggerate the vehicle's capabilities. In either case, stress that fuel economy performance is highly dependent upon driving habits and vehicle usage. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 12630 Driver/Vehicle Information Display: Description and Operation DRIVER INFORMATION CENTER (DIC) DESCRIPTION AND OPERATION DRIVER INFORMATION CENTER (DIC) The driver information center (DIC) consists of a single line 22 character vacuum fluorescent (VF) display placed in the lower center area of the instrument panel cluster (IPC). The DIC will display vehicle information, configuration, and warning parameters to the driver. The display parameters are cycled, changed, and acknowledged using 4 DIC buttons. Trip Information Button representation icon appears as a road to the horizon. - Fuel Information Button representation icon appears as a gasoline pump. - Personalization Button representation icon appears as a human next to vehicle. - Select Button representation icon appears as an arrow. DIC DISPLAYS The DIC parameters are displayed by order of priority as follows (from highest to lowest) : Service Diagnostics - Driver Identifier - Feature Programming - Driver Warnings - Vehicle Information VEHICLE INFORMATION Vehicle information provides feedback to the driver on vehicle performance, mileage, maintenance, or related information. Vehicle information can only be displayed with the ignition switch in the RUN position. When the English/Metric status changes, any applicable vehicle information data values will also change. DIC TRIP INFORMATION / RESET CAPABILITIES The available DIC Trip Information and reset capabilities are as follows: Odometer - Cannot be reset - Personal Trip Odometer - Can be reset - Business Trip Odometer - Can be reset - Timer - Can be reset - Hourmeter - Cannot be reset TRIP RESET STEM The trip reset stem on the IPC operates in the following manner with the ignition switch in the RUN position: 1. Each time the trip reset stem is pushed the display will cycle to the next trip parameter. The trip parameters are as follows: - Odometer - Personal Trip odometer - Business Trip odometer - Timer - Hourmeter 2. Holding the trip reset stem for greater than 1 second or depressing the SWC Select button while either Personal Trip or Business Trip odometer is displayed will reset the displayed trip odometer and all other corresponding trip parameters to 0.0 upon release of the stem. The trip odometer will remain displayed after being reset. 3. If a trip information parameter is being displayed, pressing the DIC Trip Information button will display the next trip information parameter. 4. If the next Trip Information parameter to be displayed is Timer, Hourmeter, or blank, pressing the reset stem will return the display to the Odometer. ODOMETER The odometer is capable of displaying values from 0 - 999,999 mi or km. If the ignition is in the OFF or UNLOCK/ACC position, the odometer can be displayed by pressing the trip reset stem. The odometer will remain displayed for 5 seconds. TRIP ODOMETERS The DIC can display Personal Trip or Business Trip odometers. The trip odometers are capable of displaying values from 0 - 999999.9 mi or km. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 12631 When the maximum value is reached, the trip odometer will roll over to 0.0. TIMER The Timer is displayed as XX (hours) : XX (minutes) : XX (seconds). The Timer is started and stopped using the DIC Select button. Holding the Select button for longer than 1 second while the Timer parameter is displayed will reset the Timer to 00:00:00. The Timer status and data value is retained in memory when the ignition is turned OFF. When the ignition is turned ON again, the Timer status and data value is resumed. The Timer maximum value is 99:59:59. When the maximum is reached, the Timer rolls over to 00:00:00 and continues to operate. FUEL INFORMATION DIC Fuel Information / Reset Capabilities The available DIC Fuel Information and reset capabilities are as follows: Range. Can not be reset - Avg. Fuel Economy. Can be reset - Inst. Fuel Economy. Can not be reset - Engine Oil Life. Can be reset Range The range display is the estimated distance that the vehicle can travel under current fuel economy and fuel level conditions. This range is calculated from odometer information and class 2 messages. Fuel Range is capable of displaying values from 0-999 mi or km. Display appears as: RANGE: XXX MILES (English), RANGE: XXX km (Metric). If the range is less than 40 miles, RANGE: LOW will be displayed. Average Fuel Economy The Average Fuel Economy (AFE) value is calculated by the cluster based on Trip Distance and Trip Fuel Used. Pressing the Select button for longer than 1 second while the Average Fuel Economy is displayed in the DIC will reset to 0.0. Average Fuel Economy is capable of displaying values from 0.0-99.9. Display appears as: AVG ECON XX.X (English) MPG, AVG ECON XX.X L/100km (Metric). Trip Distance and Trip Fuel Used accumulated values are stored in memory when the ignition is turned OFF. Instantaneous Fuel Economy Instantaneous Fuel Economy values are calculated by the cluster from odometer information and class 2 messages. The cluster calculates instantaneous fuel economy based on distance and fuel. Instantaneous fuel economy is capable of displaying values from 0.0 - 99.9. Display appears as INST ECON XX.X (English), INST ECON XX.X L/100km (Metric). Values for the Instantaneous fuel economy are not stored when the ignition is turned OFF. Engine Oil Life Engine Oil Life percentage values are based on class 2 messages to the IPC. The IPC requests this value when Engine Oil Life is selected on the DIC. Engine Oil Life is capable of displaying values from 0-100 percent and the OIL LIFE RESET driver warning will be displayed. Pressing the Select button for longer than 5 seconds while Engine Oil Life is displayed on the DIC the value will reset to 100 percent. Display appears as ENGINE OIL LIFE: XXX%. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 12632 Feature Programming Refer to Personalization Description and Operation in Personalization. Driver Warnings For the list of Driver Warnings, refer to Indicator/Warning Message Description and Operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12641 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12642 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12643 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12644 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12645 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12646 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12647 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12648 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12649 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12650 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12651 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12652 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12653 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12654 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12655 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12656 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12657 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12658 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12659 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12660 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12661 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12662 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12663 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12664 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12665 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12666 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12667 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12668 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12669 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12670 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12671 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12672 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12673 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12674 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 12680 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: Customer Interest OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED > Page 12685 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 12690 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 12695 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 12696 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 12702 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12711 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12712 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12713 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12714 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12715 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12716 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12717 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12718 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12719 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12720 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12721 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12722 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12723 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12724 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12725 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12726 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12727 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12728 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12729 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12730 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12731 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12732 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12733 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12734 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12735 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12736 Circuit/System Testing Component Testing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12741 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12742 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12743 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12744 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12745 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12746 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12747 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12748 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12749 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12750 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12751 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12752 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12753 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12754 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12755 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12756 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12757 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12758 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12759 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12760 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12761 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12762 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12763 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12764 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12765 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12766 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12767 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12768 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12769 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12770 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12771 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12772 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12773 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12774 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 12779 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 12780 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 12781 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 12782 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 12783 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 12784 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 12785 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 12786 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 12787 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 12788 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 12789 Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 12790 Labor Time Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 12795 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: All Technical Service Bulletins OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED > Page 12804 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 12813 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 12818 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 12819 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-42-002A > Jan > 07 > Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-42-002A > Jan > 07 > Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. > Page 12825 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12835 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12836 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12837 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12838 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12839 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12840 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12841 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12842 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12843 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12844 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12845 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12846 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12847 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12848 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12849 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12850 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12851 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12852 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12853 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12854 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12855 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12856 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12857 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12858 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12859 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 12860 Circuit/System Testing Component Testing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12865 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12866 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12867 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12868 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12869 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12870 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12871 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12872 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12873 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12874 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12875 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12876 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12877 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12878 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12879 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12880 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12881 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12882 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12883 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12884 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12885 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12886 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12887 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12888 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12889 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12890 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12891 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12892 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12893 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12894 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12895 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12896 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12897 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 12898 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 12903 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 12904 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 12905 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 12906 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 12907 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 12908 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 12909 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 12910 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 12911 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 12912 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 12913 Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 12914 Labor Time Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 12919 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Technical Service Bulletins > Customer Interest: > 07-08-44-016A > Aug > 07 > Entertainment System - DVD Monitor Display Inoperative Television / Monitor: Customer Interest Entertainment System - DVD Monitor Display Inoperative Bulletin No.: 07-08-44-016A Date: August 28, 2007 TECHNICAL Subject: GM Accessories Headrest DVD System Display Monitor Inoperative (Install Cable Connector Clamps) Models Supercede: This bulletin is being revised to update the models affected list. Please discard Corporate Bulletin Number 07-08-44-016 (Section 08 - Body & Accessories). Condition Some customers may comment on an inoperative display monitor or monitors in the GM Accessories Headrest DVD System. Cause This condition may be caused by a loose connection at the display monitor cable connectors. These connectors are located at the lower rear part of both front seats. Two cables are routed to the display monitor in each seat. Correction A number of headrest monitors have been replaced under warranty and in many cases, no trouble was found by the supplier when these units were Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Technical Service Bulletins > Customer Interest: > 07-08-44-016A > Aug > 07 > Entertainment System - DVD Monitor Display Inoperative > Page 12937 analyzed. Therefore, technicians should be checking for loose connections and installing cable connector clamps to ensure a positive and robust connection. Technicians are to install a video cable connector clamp on each cable connector located under each front seat. A total of four cable connector clamps, P/N 19159659, are required for each vehicle. The illustration above shows a pair of display monitor cable connectors without the cable clamps installed. The illustration above shows the display monitor cable connectors with the cable connector clamps. The lower cable connector clamp is installed but not locked together. The upper cable connector clamp is closed and locked. The cable connector clamps have now been added as a permanent component to all GM Accessories Headrest DVD Systems installation kits. Parts Information Warranty Information (excluding Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Technical Service Bulletins > Customer Interest: > 07-08-44-016A > Aug > 07 > Entertainment System - DVD Monitor Display Inoperative > Page 12938 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-08-44-016A > Aug > 07 > Entertainment System - DVD Monitor Display Inoperative Television / Monitor: All Technical Service Bulletins Entertainment System - DVD Monitor Display Inoperative Bulletin No.: 07-08-44-016A Date: August 28, 2007 TECHNICAL Subject: GM Accessories Headrest DVD System Display Monitor Inoperative (Install Cable Connector Clamps) Models Supercede: This bulletin is being revised to update the models affected list. Please discard Corporate Bulletin Number 07-08-44-016 (Section 08 - Body & Accessories). Condition Some customers may comment on an inoperative display monitor or monitors in the GM Accessories Headrest DVD System. Cause This condition may be caused by a loose connection at the display monitor cable connectors. These connectors are located at the lower rear part of both front seats. Two cables are routed to the display monitor in each seat. Correction A number of headrest monitors have been replaced under warranty and in many cases, no trouble was found by the supplier when these units were Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-08-44-016A > Aug > 07 > Entertainment System - DVD Monitor Display Inoperative > Page 12944 analyzed. Therefore, technicians should be checking for loose connections and installing cable connector clamps to ensure a positive and robust connection. Technicians are to install a video cable connector clamp on each cable connector located under each front seat. A total of four cable connector clamps, P/N 19159659, are required for each vehicle. The illustration above shows a pair of display monitor cable connectors without the cable clamps installed. The illustration above shows the display monitor cable connectors with the cable connector clamps. The lower cable connector clamp is installed but not locked together. The upper cable connector clamp is closed and locked. The cable connector clamps have now been added as a permanent component to all GM Accessories Headrest DVD Systems installation kits. Parts Information Warranty Information (excluding Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-08-44-016A > Aug > 07 > Entertainment System - DVD Monitor Display Inoperative > Page 12945 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Television / Monitor: > NHTSA04V225000 > May > 04 > Recall 04V225000: Child Seat Anchorage Non-Compliance Child Seat: All Technical Service Bulletins Recall 04V225000: Child Seat Anchorage Non-Compliance Make / Models : Model/Build Years: Chevrolet / Express 2003 Chevrolet / Silverado 2003-2004 GMC / Savana 2003 GMC / Sierra 2003-2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID Number : 04V225000 Recall Date : MAY 10, 2004 COMPONENT: Seat Belts: Front: Anchorage Potential Number Of Units Affected : 736 SUMMARY: certain extended and regular cab pickup trucks and cargo vans converted to compressed natural gas (CNG) fail to conform to the requirements of Federal Motor Vehicle Safety Standard NO. 225, "Child Restraint Anchorage Systems." These vehicles have one seating position, the center rear seat, equipped with child restraint lower anchorages. CONSEQUENCE: The standard requires child seat lower anchorages in two seating positions for vehicles with three rear seating positions. The standard cab and cargo van vehicles, which only have front seating positions, have an air bag off switch to disable the front passenger air bag and do not have child restraint lower anchorages in the passenger seat. The standard requires passenger seat child seat lower anchorages in vehicles with an air bag off switch. however, the standard does not require vehicles with only front seating positions to have lower anchorage provisions if the vehicle is not equipped with an air bag off switch. REMEDY: To bring the standard cab and cargo van vehicles into compliance, dealers will inject epoxy into the air bag off switch to prevent air bag activation, relocate the switch behind the instrument panel and then install a cover over the resulting opening. The sun visor label and owner's manual will also be changed. the correction for the extended cab vehicle will consist of changing the front passenger seat to a seat that has child restraint lower anchorages. The recall began on September 9, 2004. Owners should contact Chevrolet at 1-800-630-2438 OR GMC AT 1-866-996-9463. NOTES: GM Recall NO. 04038. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Customer Interest for DVD Player: > 07-08-44-016A > Aug > 07 > Entertainment System - DVD Monitor Display Inoperative DVD Player: Customer Interest Entertainment System - DVD Monitor Display Inoperative Bulletin No.: 07-08-44-016A Date: August 28, 2007 TECHNICAL Subject: GM Accessories Headrest DVD System Display Monitor Inoperative (Install Cable Connector Clamps) Models Supercede: This bulletin is being revised to update the models affected list. Please discard Corporate Bulletin Number 07-08-44-016 (Section 08 - Body & Accessories). Condition Some customers may comment on an inoperative display monitor or monitors in the GM Accessories Headrest DVD System. Cause This condition may be caused by a loose connection at the display monitor cable connectors. These connectors are located at the lower rear part of both front seats. Two cables are routed to the display monitor in each seat. Correction A number of headrest monitors have been replaced under warranty and in many cases, no trouble was found by the supplier when these units were Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Customer Interest for DVD Player: > 07-08-44-016A > Aug > 07 > Entertainment System - DVD Monitor Display Inoperative > Page 12964 analyzed. Therefore, technicians should be checking for loose connections and installing cable connector clamps to ensure a positive and robust connection. Technicians are to install a video cable connector clamp on each cable connector located under each front seat. A total of four cable connector clamps, P/N 19159659, are required for each vehicle. The illustration above shows a pair of display monitor cable connectors without the cable clamps installed. The illustration above shows the display monitor cable connectors with the cable connector clamps. The lower cable connector clamp is installed but not locked together. The upper cable connector clamp is closed and locked. The cable connector clamps have now been added as a permanent component to all GM Accessories Headrest DVD Systems installation kits. Parts Information Warranty Information (excluding Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Customer Interest for DVD Player: > 07-08-44-016A > Aug > 07 > Entertainment System - DVD Monitor Display Inoperative > Page 12965 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > All Technical Service Bulletins for DVD Player: > 07-08-44-016A > Aug > 07 > Entertainment System - DVD Monitor Display Inoperative DVD Player: All Technical Service Bulletins Entertainment System - DVD Monitor Display Inoperative Bulletin No.: 07-08-44-016A Date: August 28, 2007 TECHNICAL Subject: GM Accessories Headrest DVD System Display Monitor Inoperative (Install Cable Connector Clamps) Models Supercede: This bulletin is being revised to update the models affected list. Please discard Corporate Bulletin Number 07-08-44-016 (Section 08 - Body & Accessories). Condition Some customers may comment on an inoperative display monitor or monitors in the GM Accessories Headrest DVD System. Cause This condition may be caused by a loose connection at the display monitor cable connectors. These connectors are located at the lower rear part of both front seats. Two cables are routed to the display monitor in each seat. Correction A number of headrest monitors have been replaced under warranty and in many cases, no trouble was found by the supplier when these units were Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > All Technical Service Bulletins for DVD Player: > 07-08-44-016A > Aug > 07 > Entertainment System - DVD Monitor Display Inoperative > Page 12971 analyzed. Therefore, technicians should be checking for loose connections and installing cable connector clamps to ensure a positive and robust connection. Technicians are to install a video cable connector clamp on each cable connector located under each front seat. A total of four cable connector clamps, P/N 19159659, are required for each vehicle. The illustration above shows a pair of display monitor cable connectors without the cable clamps installed. The illustration above shows the display monitor cable connectors with the cable connector clamps. The lower cable connector clamp is installed but not locked together. The upper cable connector clamp is closed and locked. The cable connector clamps have now been added as a permanent component to all GM Accessories Headrest DVD Systems installation kits. Parts Information Warranty Information (excluding Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > All Technical Service Bulletins for DVD Player: > 07-08-44-016A > Aug > 07 > Entertainment System - DVD Monitor Display Inoperative > Page 12972 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Page 12973 DVD Player: Description and Operation DVD PLAYER DVD Player The DVD player and the video display screen are located in the overhead console. The DVD player can be controlled by both the buttons on the DVD player and by the buttons on the remote control. The DVD player power may be turned on when the ignition is in the run, accessory, or retained accessory power (RAP) power modes. DVDs are manufactured with different region codes based on the country in which they are sold. Therefore, the RSE system DVD player is only compatible with the region code where the vehicle is sold. The DVD region code is printed on the jacket of most DVDs. The DVD player will also play audio CDs. Home recorded CDs, CD-R or CD-RW formats, will not play in this DVD player. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Service and Repair > Remote Control Battery Replacement DVD Player: Service and Repair Remote Control Battery Replacement BATTERY REPLACEMENT To change the batteries, do the following: 1. Remove the battery compartment door located on the bottom of the remote control. 2. Remove the batteries from the compartment. 3. Replace the 2 AA-size batteries in the proper orientation. If the remote control is to be stored for a long period of time, remove the batteries and keep them in a cool, dry place. Do not store the remote control in heat or direct sunlight. This could damage the remote control and would not be covered by your vehicle warranty. Keep the remote control stored in a cool, dry place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Service and Repair > Remote Control Battery Replacement > Page 12976 DVD Player: Service and Repair DVD Player Replacement (2ND Row) DVD PLAYER REPLACEMENT (2ND ROW) TOOLS REQUIRED J 38778 Door Trim Pad Clip Remover REMOVAL PROCEDURE IMPORTANT: Components of the DVD player cannot be serviced separately. Replace as an assembly. 1. Move the screen to the open position. 2. Remove the rear screw cover using a flat bladed tool. 3. Remove the four retaining bolts (2). 4. Insert the J 38778 between the headliner and the DVD player assembly. 5. With 1 hand holding the DVD player assembly, pry the retainer from the bracket. 6. Allow the DVD player assembly to come to rest on the hook. IMPORTANT: Observe the routing of the wiring harness (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Service and Repair > Remote Control Battery Replacement > Page 12977 7. Disconnect the wire connector (1). 8. Slightly lift up the DVD player assembly so that the hook can be removed from its resting position. 9. Remove the DVD player from the vehicle. INSTALLATION PROCEDURE 1. Install the DVD player hook (1) into the hook opening. 2. Connect the wire connector (1) to the DVD player assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Service and Repair > Remote Control Battery Replacement > Page 12978 IMPORTANT: Ensure the harness is routed to the right side of the large plastic pin as shown (2). 3. Install the harness retainer to the panel. 4. Swing the rear part of the assembly to the headliner so that the retainer is seated. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the two rear retaining bolts. Tighten Tighten the 2 rear retaining bolts to 9 N.m (80 lb in). 6. Move the screen to the open position. 7. Install the 2 front retaining bolts (2). Tighten Tighten the 2 front retaining bolts to 9 N.m (80 lb in). 8. Install the rear screw cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Headphones / Earphones > Component Information > Technical Service Bulletins > Entertainment System - Headphone Foam Pad Replacement Headphones / Earphones: Technical Service Bulletins Entertainment System - Headphone Foam Pad Replacement Bulletin No.: 05-08-44-005A Date: July 19, 2007 INFORMATION Subject: Information on Rear Seat Headphone Foam Ear Pad Replacement if Worn or Damaged Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2, H3 2005-2008 Saab 9-7X with Rear Seat Entertainment System (RPOs U32, U42) Supercede: This bulletin is being revised to add models and model years and update the shipping costs. Please discard Corporate Bulletin Number 05-08-44-005 (Section 08 - Body and Accessories). Foam ear pads on the rear headphone may become worn or damaged. The headphone foam ear pads may wear out when not handled and stored carefully. If the headphone foam ear pads become damaged or worn out, the foam pads can be replaced separately from the headphone set. It is not necessary to replace the complete headphone set. Parts Information All pricing information listed in this bulletin is in U.S. dollars and is subject to change without notice. The headphone replacement foam ear pads can be ordered in pairs directly through the supplier. Have your customer call Unwired at 1-888-293-3332, then prompt zero (0). The replacement, P/N CS-980 (thick earfoam), can be ordered for $3.50 (USD) per pair plus $2.50 USPS shipping. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Specifications > Page 12986 Overhead Console - Garage Door Opener Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions Garage Door Opener Transmitter: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12989 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12990 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12991 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12992 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12993 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12994 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12995 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12996 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12997 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12998 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 12999 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13000 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13001 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13002 Garage Door Opener Transmitter: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13003 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13004 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13005 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13006 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13007 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13008 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13009 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13010 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13011 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13012 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13013 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13014 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13015 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13016 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13017 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13018 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13019 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13020 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13021 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13022 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13023 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13024 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13025 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13026 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13027 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13028 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13029 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13030 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13031 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13032 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13033 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13034 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13035 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13036 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13037 Garage Door Opener Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 13038 Garage Door Opener Transmitter: Electrical Diagrams Garage Door Opener Diagram Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Page 13039 Garage Door Opener Transmitter: Description and Operation GARAGE DOOR OPENER DESCRIPTION AND OPERATION The garage door opener is located in the overhead console. The valet switch provides battery voltage to the garage door opener. If battery voltage is lost due to a condition such as a dead battery, the garage door opener unit relies on the non-serviceable internal power backup supply. The unit is programmed using the customer's hand-held transmitters for the garage doors, electric entrance gates, or lighting and security systems. The garage door opener is rolling code capable. Rolling code is a system that allows the code that the customers receiver receives from the garage door opener to change every time the garage door opener is used within operating range of the receiver. When the receiver and the garage door opener are initially programmed together, a code is established, a new code is created for every new transmission. The software in the receiver recognizes the garage door opener and accepts the new code. The garage door opener is compatible with most, but not all types and brands of transmitters. If a problem should occur with a compatibility conflict with a transmitter, call HomeLink(TM) at 1-800-355-3515. The garage door opener is a transmitter operating between 288-399 MHz. The power and range of the transmitter is limited to comply with laws governing the generation of radio frequency interference (RFI). The transmitter is programmed by the user to accept the signal generated by the user's transmitters, refer to Garage Door Opener Programming - Universal. The garage door opener has 3 buttons that may be programmed for individual transmitter/receiver combinations to control up to 3 garage door openers, security gates, and lighting systems. Each button represents a transmitter code section of the transmitter, which operates separately from any other button, and may be considered a separate transmitter. Operation consists of simply pressing a button to activate the corresponding transmitter. Battery voltage is provided to the garage door opener from the IGN SEN fuse in the IP fuse block. The garage door opener is grounded through G400. Inadvertent power is supplied from the body control module (BCM). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Garage Door Opener Transmitter: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT - GARAGE DOOR OPENER Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure to use when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Garage Door Opener in order to identify the correct procedure for diagnosing the system and where the procedure is located. See: Symptom Related Diagnostic Procedures/Garage Door Opener Inoperative Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 13042 Garage Door Opener Transmitter: Symptom Related Diagnostic Procedures - Symptoms - Garage Door Opener SYMPTOMS - GARAGE DOOR OPENER IMPORTANT: Review the system description and operation in order to familiarize yourself with the system functions. Refer to Garage Door Opener Description and Operation. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the garage door opener. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to Garage Door Opener Inoperative in order to diagnose the symptom. Steps 1-3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 13043 Steps 4-11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Garage Door Opener Replacement Garage Door Opener Transmitter: Service and Repair Garage Door Opener Replacement GARAGE DOOR OPENER REPLACEMENT REMOVAL PROCEDURE 1. Remove the console roof screw. 2. Disconnect the electrical connectors. 3. Remove the console from vehicle. 4. Disconnect the electrical connector from the garage door opener. 5. Remove the garage door opener retaining screws. 6. Remove the garage door opener from the overhead console. INSTALLATION PROCEDURE 1. Install the garage door opener to the overhead console. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the garage door opener retaining screws. Tighten Tighten the retaining screws to 2 N.m (18 lb in). 3. Connect the electrical connector to the garage door opener. 4. Install the console to the roof. 5. Connect the electrical connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Garage Door Opener Replacement > Page 13046 6. Install the overhead console retaining screw. Tighten Tighten the overhead console retaining screw to 2 N.m (18 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Garage Door Opener Replacement > Page 13047 Garage Door Opener Transmitter: Service and Repair Garage Door Opener Programming Universal GARAGE DOOR OPENER PROGRAMMING - UNIVERSAL GARAGE DOOR OPENER PROGRAMMING IMPORTANT: Do not use the garage door opener (GDO) with any garage door opener that does not have the stop and reverse safety feature. This includes any garage door opener model manufactured before April 1, 1982. Be sure that people and objects are clear of the garage door you are programming. The GDO is programmed by using the customer's hand-held transmitter(s). Turn the ignition OFF while programming the GDO transmitter. Follow these steps to program up to 3 channels: 1. If you have previously programmed a transmitter, proceed to Step 2. Otherwise, hold down the 2 outside buttons on the GDO transmitter for approximately 20 seconds, until the light on the GDO transmitter begins to flash rapidly. Then release the buttons. This procedure erases any previous settings and initializes the memory for all 3 channels. 2. Decide which of the 3 channels you want to program to the transmitter you have. 3. Hold the end of the hand-held transmitter against the front surface of the GDO (less than 1 inch) so you can still see the light. 4. Using both hands, press the hand-held transmitter button and the desired button on the GDO transmitter. Continue to hold both buttons through Step 5. IMPORTANT: The GDO is compatible with most, but not all, types and brands of transmitters. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the transmitter used to program the GDO. Call HomeLink(tm) at 1-800-355-3515 in order to address this problem. 5. Hold down the buttons on both transmitters until you see the light on the GDO transmitter flash slowly and then rapidly. The rapid flashing, which could take up to 90 seconds, indicates that the GDO transmitter has been programmed. Release the buttons on both transmitters when the light starts to flash rapidly. TRAINING THE GDO FOR ROLLING CODE RECEIVERS This procedure is for training the customer's rolling code garage door openers to their GDO transmitter. The GDO must already be programmed to its hand-held transmitter. The training process below must be completed within 30 seconds or it must be repeated. 1. Locate the train button on the garage door opener receiver. Refer to the operator's manual for the garage door opener (or call HomeLink(tm) at 1-800-355-3515 for assistance). Follow instructions for the garage door opener in order to determine when the unit is in train mode. 2. Return to the GDO transmitter in the vehicle, and press the button that you want trained for rolling codes 3 times, for 1 second each time. If not successfully programmed, try 2-5 seconds each time. 3. Press the button used again in order to verify that the GDO transmitter has been programmed. You may use either the hand-held transmitter or the GDO to open the garage door. The GDO is compatible with most, but not all, types and brands of transmitters. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the transmitter used to program the GDO. Call HomeLink(TM) at 1-800-355-3515 in order to address compatibility concerns. ERASING CHANNELS To erase programmed channels, hold down the 2 outside buttons until the light on the GDO transmitter begins to flash. Individual channels cannot be erased, but can be reprogrammed using the Garage Door Opener Programming and the Training GDO for Rolling Code Receivers procedures. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Garage Door Opener Replacement > Page 13048 NON-COMPATIBLE GARAGE DOOR OPENERS Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Page 13049 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 13055 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Service and Repair > Coaxial Cable - Navigation and Cellular Telephone Antenna Global Positioning System Antenna: Service and Repair Coaxial Cable - Navigation and Cellular Telephone Antenna COAXIAL CABLE REPLACEMENT - NAVIGATION AND CELLULAR TELEPHONE ANTENNA REMOVAL PROCEDURE 1. Remove the I/P trim panel. 2. Lower the headliner. 3. Disconnect the cables from the antenna base. IMPORTANT: Observe the routing of the cables. 4. Remove the cable retainers from the roof and pillar. 5. Disconnect the cable (3) from the module. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Service and Repair > Coaxial Cable - Navigation and Cellular Telephone Antenna > Page 13058 1. Install the cable retainers to the roof and pillar. 2. Connect the cables (3) to the module. 3. Connect the cables to the antenna base. IMPORTANT: Ensure the cables are routed properly and there is no sharp bends in the cables. 4. Install the headliner. 5. Install the I/P trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Service and Repair > Coaxial Cable - Navigation and Cellular Telephone Antenna > Page 13059 Global Positioning System Antenna: Service and Repair Antenna Assembly Replacement - Cellular and Navigation ANTENNA ASSEMBLY REPLACEMENT - CELLULAR AND NAVIGATION REMOVAL PROCEDURE 1. Lower the headliner. Refer to Headliner Replacement in Interior Trim 2. Disconnect the cables from the antenna. 3. Loosen the retaining nut until the antenna assembly can be pulled from the top of the roof. INSTALLATION PROCEDURE 1. Place the antenna assembly on the roof opening. NOTE: Refer to Fastener Notice in Service Precautions. 2. Tighten the retaining nut. Tighten Tighten the nut to 6 N.m (53 lb in). 3. Connect the antenna cables. 4. Install the headliner. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Service and Repair Global Positioning System Module: Service and Repair COMMUNICATION INTERFACE MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The vehicle communication interface module (VCIM) has a specific set of unique numbers that tie the module to each vehicle. These numbers, the 10-digit station identification (STID) and the 11-digit electronic serial number (ESN), are used by the National Cellular Network and Onstar(R) to identify the specific vehicle. Because these numbers are tied to the vehicle identification number of the vehicle, you must never exchange these parts with those of another vehicle. 1. Remove the instrument panel (I/P) top trim panel. 2. Disconnect the wire connectors (2) from the module. 3. Disconnect the coaxial cable (3) from the module. 4. Remove the nuts (2) retaining the module to the bracket. 5. Remove the module (3) from the vehicle. INSTALLATION PROCEDURE 1. If replacing the VCIM, record the 10-digit STID number, and the 11-digit ESN number from the labels on the new module. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Service and Repair > Page 13063 2. Install the module on the bracket. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the retaining nuts (2). Tighten Tighten the nuts to 1.6 N.m (14 lb in). 4. Connect the coaxial cable (3) to the module. 5. Connect the wire connectors (2) to the module. 6. Install the I/P trim panel. IMPORTANT: After replacing the vehicle communication interface module, you must reconfigure the Onstar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. In addition, pressing and holding the white dot button on the keypad will NOT reset this version of the Onstar(R) system. This action will cause a DTC to set. 7. Reconfigure the Onstar(R) system. Refer to OnStar Reconfiguration. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Technical Service Bulletins > Customer Interest for Memory Positioning Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation Memory Positioning Module: Customer Interest Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Technical Service Bulletins > Customer Interest for Memory Positioning Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 13073 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Technical Service Bulletins > Customer Interest for Memory Positioning Module: > 04-08-50-003 > Feb > 04 > Interior - Seat Memory Feature Appears Inoperative Memory Positioning Module: Customer Interest Interior - Seat Memory Feature Appears Inoperative Bulletin No.: 04-08-50-003 Date: February 26, 2004 INFORMATION Subject: Enabling Memory Seat Feature via DIC If Feature Appears Inoperative Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon Denali, Yukon Denali XL 2003-2004 HUMMER H2 with Steering Wheel Controls (RPO UK3) (standard on H2) If the memory seat feature appears inoperative, check the Driver Information Center (DIC). Many of the memory seat modules that were returned through the Warranty Parts Center for a condition of inoperative have shown No Trouble Found. The Driver Information Center (DIC), programmed for Seat Entry and Exit, is set to the default "Off" mode at the assembly plant. DO NOT REPLACE THE MEMORY SEAT MODULE. Perform the following procedure. Important: The following procedure will need to be completed for each Remote/Key selection. Using the DIC menu, do the following steps: 1. Set the "Seat Recall" to either "At Key In" or "On Remote" based on the customer's preference. 2. Set the "Exit Seat" to "On". 3. Adjust the following items: Memory Seat: 3.1. Driver's Seat (including the seat back, recliner, lumbar, and side wings) 3.2. Throttle and Brake Pedals (not available on H2 or Silverado and Sierra Trucks) 3.3. Outside Mirrors 3.4. Radio Station Presets 3.5. Last Chosen Climate Control System Settings (not available on Silverado or Sierra Trucks) 3.6. Press and hold the "1" or "2" (for driver 1 or 2) button of the memory control for three seconds. A double chime will sound to let you know that the position has been stored. Easy Exit Seat: 3.1. Press and release the 1 or 2 button or press the unlock button on the desired remote keyless entry transmitter. The seat will move to the stored memory position. 3.2. Adjust the seat to the desired exit position. 3.3. Press and hold the exit button of the memory control (located on the door) for three seconds. A double chime will sound to let you know that the position has been stored for the identified driver (1 or 2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Technical Service Bulletins > Customer Interest for Memory Positioning Module: > 04-08-50-003 > Feb > 04 > Interior - Seat Memory Feature Appears Inoperative > Page 13078 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Memory Positioning Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation Memory Positioning Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Memory Positioning Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 13084 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Memory Positioning Module: > 04-08-50-003 > Feb > 04 > Interior - Seat Memory Feature Appears Inoperative Memory Positioning Module: All Technical Service Bulletins Interior - Seat Memory Feature Appears Inoperative Bulletin No.: 04-08-50-003 Date: February 26, 2004 INFORMATION Subject: Enabling Memory Seat Feature via DIC If Feature Appears Inoperative Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon Denali, Yukon Denali XL 2003-2004 HUMMER H2 with Steering Wheel Controls (RPO UK3) (standard on H2) If the memory seat feature appears inoperative, check the Driver Information Center (DIC). Many of the memory seat modules that were returned through the Warranty Parts Center for a condition of inoperative have shown No Trouble Found. The Driver Information Center (DIC), programmed for Seat Entry and Exit, is set to the default "Off" mode at the assembly plant. DO NOT REPLACE THE MEMORY SEAT MODULE. Perform the following procedure. Important: The following procedure will need to be completed for each Remote/Key selection. Using the DIC menu, do the following steps: 1. Set the "Seat Recall" to either "At Key In" or "On Remote" based on the customer's preference. 2. Set the "Exit Seat" to "On". 3. Adjust the following items: Memory Seat: 3.1. Driver's Seat (including the seat back, recliner, lumbar, and side wings) 3.2. Throttle and Brake Pedals (not available on H2 or Silverado and Sierra Trucks) 3.3. Outside Mirrors 3.4. Radio Station Presets 3.5. Last Chosen Climate Control System Settings (not available on Silverado or Sierra Trucks) 3.6. Press and hold the "1" or "2" (for driver 1 or 2) button of the memory control for three seconds. A double chime will sound to let you know that the position has been stored. Easy Exit Seat: 3.1. Press and release the 1 or 2 button or press the unlock button on the desired remote keyless entry transmitter. The seat will move to the stored memory position. 3.2. Adjust the seat to the desired exit position. 3.3. Press and hold the exit button of the memory control (located on the door) for three seconds. A double chime will sound to let you know that the position has been stored for the identified driver (1 or 2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Memory Positioning Module: > 04-08-50-003 > Feb > 04 > Interior - Seat Memory Feature Appears Inoperative > Page 13089 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Calibration Procedure Memory Positioning Module: Service and Repair Memory Seat Calibration Procedure MEMORY SEAT CALIBRATION PROCEDURE The memory seat module uses position sensor inputs to establish soft stop locations for the adjuster motors several millimeters ahead of the physical limits of the adjuster assembly. After replacing a memory seat module or adjuster components, it may be necessary to reset the adjuster motor soft stop locations. When the repair procedure has been completed, operate the seat adjuster switch in every direction until the seat adjuster reaches its mechanical hard stop by repeatedly pressing and releasing the switch as necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Calibration Procedure > Page 13092 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the seat cushion. 2. Disconnect the upper electrical harness connectors (3). 3. Remove the module (2) retaining screws (1). 4. Slide the module to the right to disengage the lower retainers. 5. Disconnect the lower electrical harness connectors (2). 6. Remove the module from the vehicle. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Calibration Procedure > Page 13093 1. Position the module into the vehicle. 2. Connect the lower electrical harness connectors (2). 3. Slide the module (2) to the left to engage the lower retainers. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the module retaining screws (3). Tighten Tighten the screws to 3 N.m (26 lb in). 5. Connect the upper electrical harness connectors (3). 6. Install the seat cushion. 7. If a new memory seat module was installed, calibrate the seat. Refer to Memory Seat Calibration Procedure. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations Driver Door Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 13097 Seat Memory Switch: Diagrams Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 13098 Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 13099 Memory/Heated Seat Switch - Driver (DDM C5) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 13100 Memory/Heated Seat Switch - Driver (DDM C5) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 13101 Seat Memory Switch: Service and Repair MEMORY SEAT SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connector. 3. Release the front seat memory switch assembly retaining clips in order to remove the switch. 4. Remove the front seat memory switch assembly. INSTALLATION PROCEDURE 1. Install the front seat memory switch assembly to the front trim panel by pressing into place until fully seated. 2. Connect the electrical connector to the front seat memory switch assembly. 3. Install the front trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 13110 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 13111 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 13112 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13117 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13118 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13119 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13120 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13121 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13122 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13123 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13124 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13125 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13126 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13127 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13128 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13129 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13130 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13131 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13132 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13133 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13134 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13135 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13136 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13137 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13138 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13139 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13140 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13141 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13142 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13143 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13144 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13145 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13146 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13147 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13148 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13149 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13150 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 13156 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Navigation System: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 13161 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 13167 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 10-08-44-006 > Oct > 10 > Navigation - Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update Program INFORMATION Bulletin No.: 06-08-44-012E Date: April 20, 2010 Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update Discs and Ordering Information Models: 2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and Used Car Department. This bulletin ONLY applies to North American dealers/retailers. Supercede: This bulletin is being revised to include the 2010 model year and update the usage table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and Accessories). DVD Navigation Update Program The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the functionality of the navigation system declines. Offering GM customers new navigation DVDs will ensure that the customers have the latest information for their system. General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles. This program concluded on December 31, 2009. The DVD Navigation Update Program policy has changed and customers are no longer eligible for free annual updates, however, a navigation DVD update disc can be purchased for $199 (USD) + shipping. If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD). The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the GM Navigation Disc Center, as this option is not available on the website. The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an updated disc: - Via the web through gmnavdisc.com - GM Navigation Disc Center Navigation Disc Diagnostic Aid The following table can be used to identify acceptable discs for testing the navigation unit's map drive functionality. This should only be used to verify the map drive's ability to read the map disc properly and to determine if there is an issue with the unit's map drive or the disc. Some functions, such as voice recognition, may not work properly with some of the discs in the list. If the disc is found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc for the vehicle. AVN Software Update Discs Technical Service Bulletins are sometimes generated to address specific navigation radio operational or performance issues. When a navigation radio bulletin is issued, it may contain instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part number. GM dealers must order advanced vehicle navigation (AVN) software update discs as directed in the specific bulletin. AVN software update discs are for the dealer to update the navigation radio software only. They do NOT update or replace the navigation map disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will cost $50 (USD). To obtain an AVN software update disc, follow the specific ordering information provided in the bulletin. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program > Page 13176 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 10037 > Apr > 10 > Campaign Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 10037 > Apr > 10 > Campaign Unwanted Repeat Calls to OnStar(R) > Page 13181 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 10037 > Apr > 10 > Campaign Unwanted Repeat Calls to OnStar(R) > Page 13182 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 10037 > Apr > 10 > Campaign Unwanted Repeat Calls to OnStar(R) > Page 13183 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Navigation System: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13192 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13193 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13194 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13195 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13196 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13197 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13198 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13199 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13200 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13201 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13202 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13203 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13204 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13205 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13206 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13207 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13208 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13209 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13210 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13211 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13212 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13213 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13214 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13215 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13216 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13217 Circuit/System Testing Component Testing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips Navigation System: All Technical Service Bulletins Navigation Radio - Diagnostic Tips INFORMATION Bulletin No.: 08-08-44-010F Date: March 09, 2009 Subject: Navigation Radio Diagnostic Tips Models: 2008 and Prior GM Passenger Cars and Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X All Equipped with Navigation Radio Supercede: This bulletin is being revised to update the model years involved, the radio part number list, remove the PQC parts restriction and revise the diagnostic information. Please discard Corporate Bulletin Number 08-08-44-010E (Section 08 - Body and Accessories). Recent part reviews indicate that the majority of Navigation Radios returned for analysis do not test as defective. In many cases, published SI documents were available to correct the condition without the need for an exchange unit. The following Diagnostic Tips may assist with the proper diagnosis and repair of Navigation Radio Concerns. Note For U.S. dealers the 2009 and 2010 Model Year Navigation Radios are currently on restriction through the Technical Assistance Center (TAC). Refer to PI PIC5102. To order Radios and Instrument Panel Clusters (IPC) for 2008 and prior model year vehicles, please continue to follow the normal process and contact an authorized Electronic Service Center (ESC) for assistance. For any Navigation Radio replaced, a copy of the Repair Order (RO) must be included with the returned radio. Be sure to document the customer's concern in detail, including unusual noises and what functions are affected. List any Diagnostic Trouble Codes (DTCs) on the RO. Ensure the radio is sufficiently protected during shipping to prevent damage to the radio assembly. Note Navigation Radios with physical damage (for example: shattered displays, impact damage to the radio face and fluid damage) must be reviewed with the District Service Manager for appropriate coverage prior to replacing the radio. The dealership must note the District Service Manager's approval on the Repair Order, along with the reason for the goodwill assistance. Do NOT disassemble the radio to try and retrieve stuck CDs/DVDs as this may result in a debit to the dealership. Refer to Corporate Bulletin Number 08-08-44-015, Information on Inappropriate Warranty Claims submitted for Damaged Radios and Instrument Panel Clusters. Getting Started Retrieve the Navigation Radio part number using the Tech 2(R). Refer to Corporate Bulletin Number 04-08-44-005C - Utilizing Tech 2 to Retrieve Part Numbers for Radios, Compact Disc (CD) Changers and Instrument Panel Clusters (IPC). Use the table below to determine the appropriate Diagnostic Tips Review to follow based on the radio part number. Scroll down the bulletin to find the corresponding Diagnostic Tips Review. Printing This Document To print the applicable Diagnostic Tips Review pages, select File then Print Preview. Use the arrows at the top of the screen to scroll left and right through the bulletin to identify the correct pages containing the questions. With the pages identified, click on the Print button at the top left. In the pop-up box, select "Pages" in the "Print Range" and type in the pages. For example, to print pages 19 through 22, type in the box provided "19-22". Once the page range has been filled in, click the Print box at the bottom of the pop-up box. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13222 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13223 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13224 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13225 Diagnostic Tips Review Table Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13226 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13227 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13228 Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13229 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13230 Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13231 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13232 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13233 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13234 Diagnostic Tips Review # 3 - Denso Navigation Radios Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13235 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13236 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13237 Diagnostic Tips Review # 4 - Denso legacy Navigation Radio Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13238 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13239 Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13244 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13245 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13246 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13247 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13248 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13249 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13250 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13251 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13252 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13253 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13254 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13255 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13256 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13257 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13258 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13259 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13260 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13261 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13262 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13263 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13264 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13265 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13266 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13267 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13268 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13269 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13270 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13271 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13272 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13273 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13274 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13275 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13276 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13277 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13282 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13283 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13284 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13285 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13286 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13287 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13288 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13289 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13290 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13291 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13292 Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13293 Labor Time Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Navigation System: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 13298 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Navigation System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-023 > Jun > 08 > Navigation Radio - Adaptation After Radio/Battery R&R; Navigation System: All Technical Service Bulletins Navigation Radio - Adaptation After Radio/Battery R&R; INFORMATION Bulletin No.: 08-08-44-023 Date: June 18, 2008 Subject: Information On Navigation Radio Not Displaying Accurate Vehicle Location After Radio Replacement, Power Loss Or Battery Replacement Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Navigation Radio The purpose of this bulletin is to inform technicians and customers that the Navigation Radio may not display the vehicle location icon on the map accurately after a radio or battery has been replaced or after battery power has been removed from the radio. The vehicle location icon accuracy may be degraded if the GPS signal is not available and the GPS displayed icon has a red line through it. The Navigation Radio does not keep learned GPS information or gyroscope and vehicle speed signals stored when the battery power is removed from the radio. The Navigation radio continually uses GPS, gyroscope and vehicle speed data to maintain the vehicle location icon positioned accurately on the displayed map. There may be periods of time during a drive cycle when the GPS signal may not be available and the vehicle location icon still appears to be accurate. This is due to the radio having internal gyroscopes and receiving a vehicle speed signal to maintain accuracy if the radio had received a good GPS signal earlier in the drive cycle. Normal driving will improve the accuracy of the vehicle location icon on the displayed map. It may be necessary for the vehicle to be driven up to 40 km (25 mi) with 15 left and 15 right turns while the vehicle location icon is matched to roads on the displayed map. Do not replace the radio for this condition. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Navigation System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Navigation System: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 13315 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 07-08-44-007 > Apr > 07 > Navigation System - Replacement Navigation Discs Navigation System: All Technical Service Bulletins Navigation System - Replacement Navigation Discs Bulletin No.: 07-08-44-007 Date: April 17, 2007 INFORMATION Subject: Information on Obtaining Replacement Navigation Discs When Radios are Exchanged Order Replacement Navigation Disc Through Navigation Disc Center Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X with a Navigation Radio Attention: The purpose of this bulletin is to inform dealership personnel of a new procedure for obtaining a replacement navigation disc for radios that are sent to an ESC for exchange. This bulletin applies to U.S. and Canadian dealers only and is not intended for use by export dealers. When a navigation radio warranty exchange is performed, the customer must have a navigation disc to operate the new radio. If the customer's navigation disc was damaged or is stuck in the failed radio, the customer would have to wait for an excessive period of time for the disc to be returned or replaced. The Electronic Service Centers (ESC) are not authorized to remove stuck navigation discs from cores, as the cores must be returned to the supplier for analysis prior to any disassembly. The time it would take for the supplier to return the navigation disc would significantly delay the completion of the repair at the dealership. If the customer's navigation disc is damaged or cannot be removed from the radio, the dealership is to obtain an exchange radio through an ESC and a new navigation disc through the GM Navigation Disc Center. Both items can be shipped overnight to the dealership upon request. GM Navigation Disc Center Contact Information Via the web through gmnavdisc.com The GM Navigation Disc Center is also the center of expertise for navigation system questions. Warranty Information Include the part number and cost of the new navigation disc on the warranty claim for the navigation radio exchange. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) Number Incorrect/Incorrectly Assigned Navigation System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) Number Incorrect/Incorrectly Assigned > Page 13325 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 10-08-44-006 > Oct > 10 > Navigation Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update Program INFORMATION Bulletin No.: 06-08-44-012E Date: April 20, 2010 Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update Discs and Ordering Information Models: 2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and Used Car Department. This bulletin ONLY applies to North American dealers/retailers. Supercede: This bulletin is being revised to include the 2010 model year and update the usage table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and Accessories). DVD Navigation Update Program The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the functionality of the navigation system declines. Offering GM customers new navigation DVDs will ensure that the customers have the latest information for their system. General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles. This program concluded on December 31, 2009. The DVD Navigation Update Program policy has changed and customers are no longer eligible for free annual updates, however, a navigation DVD update disc can be purchased for $199 (USD) + shipping. If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD). The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the GM Navigation Disc Center, as this option is not available on the website. The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an updated disc: - Via the web through gmnavdisc.com - GM Navigation Disc Center Navigation Disc Diagnostic Aid The following table can be used to identify acceptable discs for testing the navigation unit's map drive functionality. This should only be used to verify the map drive's ability to read the map disc properly and to determine if there is an issue with the unit's map drive or the disc. Some functions, such as voice recognition, may not work properly with some of the discs in the list. If the disc is found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc for the vehicle. AVN Software Update Discs Technical Service Bulletins are sometimes generated to address specific navigation radio operational or performance issues. When a navigation radio bulletin is issued, it may contain instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part number. GM dealers must order advanced vehicle navigation (AVN) software update discs as directed in the specific bulletin. AVN software update discs are for the dealer to update the navigation radio software only. They do NOT update or replace the navigation map disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will cost $50 (USD). To obtain an AVN software update disc, follow the specific ordering information provided in the bulletin. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program > Page 13334 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 02-08-44-007D > May > 09 > OnStar(R) Negative Impact of Cloth/Vinyl Roofs Navigation System: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13343 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13344 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13345 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13346 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13347 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13348 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13349 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13350 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13351 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13352 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13353 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13354 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13355 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13356 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13357 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13358 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13359 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13360 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13361 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13362 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13363 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13364 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13365 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13366 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13367 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13368 Circuit/System Testing Component Testing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips Navigation System: All Technical Service Bulletins Navigation Radio - Diagnostic Tips INFORMATION Bulletin No.: 08-08-44-010F Date: March 09, 2009 Subject: Navigation Radio Diagnostic Tips Models: 2008 and Prior GM Passenger Cars and Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X All Equipped with Navigation Radio Supercede: This bulletin is being revised to update the model years involved, the radio part number list, remove the PQC parts restriction and revise the diagnostic information. Please discard Corporate Bulletin Number 08-08-44-010E (Section 08 - Body and Accessories). Recent part reviews indicate that the majority of Navigation Radios returned for analysis do not test as defective. In many cases, published SI documents were available to correct the condition without the need for an exchange unit. The following Diagnostic Tips may assist with the proper diagnosis and repair of Navigation Radio Concerns. Note For U.S. dealers the 2009 and 2010 Model Year Navigation Radios are currently on restriction through the Technical Assistance Center (TAC). Refer to PI PIC5102. To order Radios and Instrument Panel Clusters (IPC) for 2008 and prior model year vehicles, please continue to follow the normal process and contact an authorized Electronic Service Center (ESC) for assistance. For any Navigation Radio replaced, a copy of the Repair Order (RO) must be included with the returned radio. Be sure to document the customer's concern in detail, including unusual noises and what functions are affected. List any Diagnostic Trouble Codes (DTCs) on the RO. Ensure the radio is sufficiently protected during shipping to prevent damage to the radio assembly. Note Navigation Radios with physical damage (for example: shattered displays, impact damage to the radio face and fluid damage) must be reviewed with the District Service Manager for appropriate coverage prior to replacing the radio. The dealership must note the District Service Manager's approval on the Repair Order, along with the reason for the goodwill assistance. Do NOT disassemble the radio to try and retrieve stuck CDs/DVDs as this may result in a debit to the dealership. Refer to Corporate Bulletin Number 08-08-44-015, Information on Inappropriate Warranty Claims submitted for Damaged Radios and Instrument Panel Clusters. Getting Started Retrieve the Navigation Radio part number using the Tech 2(R). Refer to Corporate Bulletin Number 04-08-44-005C - Utilizing Tech 2 to Retrieve Part Numbers for Radios, Compact Disc (CD) Changers and Instrument Panel Clusters (IPC). Use the table below to determine the appropriate Diagnostic Tips Review to follow based on the radio part number. Scroll down the bulletin to find the corresponding Diagnostic Tips Review. Printing This Document To print the applicable Diagnostic Tips Review pages, select File then Print Preview. Use the arrows at the top of the screen to scroll left and right through the bulletin to identify the correct pages containing the questions. With the pages identified, click on the Print button at the top left. In the pop-up box, select "Pages" in the "Print Range" and type in the pages. For example, to print pages 19 through 22, type in the box provided "19-22". Once the page range has been filled in, click the Print box at the bottom of the pop-up box. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13373 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13374 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13375 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13376 Diagnostic Tips Review Table Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13377 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13378 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13379 Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13380 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13381 Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13382 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13383 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13384 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13385 Diagnostic Tips Review # 3 - Denso Navigation Radios Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13386 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13387 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13388 Diagnostic Tips Review # 4 - Denso legacy Navigation Radio Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13389 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13390 Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13395 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13396 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13397 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13398 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13399 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13400 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13401 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13402 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13403 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13404 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13405 Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13406 Labor Time Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-46-008C > Sep > 08 > OnStar(R) Analog/Digital System Information Navigation System: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-46-008C > Sep > 08 > OnStar(R) Analog/Digital System Information > Page 13411 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-46-004 > Aug > 08 > OnStar(R) Aftermarket Device Interference Information Navigation System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-023 > Jun > 08 > Navigation Radio - Adaptation After Radio/Battery R&R; Navigation System: All Technical Service Bulletins Navigation Radio - Adaptation After Radio/Battery R&R; INFORMATION Bulletin No.: 08-08-44-023 Date: June 18, 2008 Subject: Information On Navigation Radio Not Displaying Accurate Vehicle Location After Radio Replacement, Power Loss Or Battery Replacement Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Navigation Radio The purpose of this bulletin is to inform technicians and customers that the Navigation Radio may not display the vehicle location icon on the map accurately after a radio or battery has been replaced or after battery power has been removed from the radio. The vehicle location icon accuracy may be degraded if the GPS signal is not available and the GPS displayed icon has a red line through it. The Navigation Radio does not keep learned GPS information or gyroscope and vehicle speed signals stored when the battery power is removed from the radio. The Navigation radio continually uses GPS, gyroscope and vehicle speed data to maintain the vehicle location icon positioned accurately on the displayed map. There may be periods of time during a drive cycle when the GPS signal may not be available and the vehicle location icon still appears to be accurate. This is due to the radio having internal gyroscopes and receiving a vehicle speed signal to maintain accuracy if the radio had received a good GPS signal earlier in the drive cycle. Normal driving will improve the accuracy of the vehicle location icon on the displayed map. It may be necessary for the vehicle to be driven up to 40 km (25 mi) with 15 left and 15 right turns while the vehicle location icon is matched to roads on the displayed map. Do not replace the radio for this condition. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 00-08-46-004C > Jan > 08 > OnStar(R) Re-establishing OnStar(R) Communications Navigation System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 > OnStar(R) Incorrect GPS Position Reported During Call Navigation System: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 > OnStar(R) Incorrect GPS Position Reported During Call > Page 13428 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 07-08-44-007 > Apr > 07 > Navigation System - Replacement Navigation Discs Navigation System: All Technical Service Bulletins Navigation System - Replacement Navigation Discs Bulletin No.: 07-08-44-007 Date: April 17, 2007 INFORMATION Subject: Information on Obtaining Replacement Navigation Discs When Radios are Exchanged Order Replacement Navigation Disc Through Navigation Disc Center Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X with a Navigation Radio Attention: The purpose of this bulletin is to inform dealership personnel of a new procedure for obtaining a replacement navigation disc for radios that are sent to an ESC for exchange. This bulletin applies to U.S. and Canadian dealers only and is not intended for use by export dealers. When a navigation radio warranty exchange is performed, the customer must have a navigation disc to operate the new radio. If the customer's navigation disc was damaged or is stuck in the failed radio, the customer would have to wait for an excessive period of time for the disc to be returned or replaced. The Electronic Service Centers (ESC) are not authorized to remove stuck navigation discs from cores, as the cores must be returned to the supplier for analysis prior to any disassembly. The time it would take for the supplier to return the navigation disc would significantly delay the completion of the repair at the dealership. If the customer's navigation disc is damaged or cannot be removed from the radio, the dealership is to obtain an exchange radio through an ESC and a new navigation disc through the GM Navigation Disc Center. Both items can be shipped overnight to the dealership upon request. GM Navigation Disc Center Contact Information Via the web through gmnavdisc.com The GM Navigation Disc Center is also the center of expertise for navigation system questions. Warranty Information Include the part number and cost of the new navigation disc on the warranty claim for the navigation radio exchange. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program > Page 13442 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 10037 > Apr > 10 > Campaign Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 10037 > Apr > 10 > Campaign Unwanted Repeat Calls to OnStar(R) > Page 13447 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 10037 > Apr > 10 > Campaign Unwanted Repeat Calls to OnStar(R) > Page 13448 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 10037 > Apr > 10 > Campaign Unwanted Repeat Calls to OnStar(R) > Page 13449 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13458 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13459 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13460 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13461 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13462 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13463 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13464 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13465 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13466 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13467 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13468 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13469 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13470 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13471 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13472 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13473 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13474 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13475 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13476 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13477 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13478 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13479 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13480 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13481 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13482 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 13483 Circuit/System Testing Component Testing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13488 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13489 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13490 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13491 Diagnostic Tips Review Table Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13492 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13493 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13494 Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13495 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13496 Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13497 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13498 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13499 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13500 Diagnostic Tips Review # 3 - Denso Navigation Radios Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13501 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13502 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13503 Diagnostic Tips Review # 4 - Denso legacy Navigation Radio Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13504 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 13505 Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13510 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13511 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13512 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13513 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13514 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13515 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13516 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13517 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13518 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13519 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13520 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13521 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13522 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13523 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13524 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13525 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13526 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13527 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13528 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13529 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13530 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13531 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13532 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13533 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13534 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13535 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13536 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13537 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13538 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13539 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13540 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13541 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13542 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 13543 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13548 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13549 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13550 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13551 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13552 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13553 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13554 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13555 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13556 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13557 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13558 Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 13559 Labor Time Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-46-008C > Sep > 08 > OnStar(R) Analog/Digital System Information > Page 13564 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Description and Operation Pedal Positioning Switch: Description and Operation Brake Pedal Position Sensor Calibration Description and Operation Calibration Criteria The brake pedal position (BPP) sensor receives a low reference signal and a 5-volt reference signal from the electro-hydraulic power steering (EHPS). Whenever the brake pedal is applied, the brake pedal position sensor applies a variable voltage signal to the EHPS through the BPP sensor signal circuit. Brake pedal position sensor calibration must be performed after the brake pedal position sensor or EHPS system have been serviced. The calibration procedure will set brake pedal position sensor home value. This value is used by the EHPS to determine the brake pedal position and the brake pedal rate. These two outputs are provided to the hybrid control module (HCM) via GMLAN. Calibration Procedure 1. Install a scan tool. 2. Turn ON the ignition, with the engine OFF. 3. Important: Make sure the brake pedal is not depressed before sending BPP sensor calibration command. Navigate to the Special Functions screen on the scan tool and select BPP Sensor Calibration in order to perform the brake pedal position sensor calibration. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Description and Operation > Page 13585 Pedal Positioning Switch: Service and Repair Brake Pedal Position Sensor Replacement Removal Procedure 1. Important: Once the Brake Pedal Position Sensor bolt is removed for any reason, a new 4 mm bolt, with fresh LOCTITETM will need to be installed. Remove the brake pedal position sensor bolt (1). 2. Remove the brake pedal position sensor (2) from the mounting bracket. 3. Disconnect the brake pedal position sensor electrical connector (1). 4. Remove the brake pedal position sensor (2) from the vehicle Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Description and Operation > Page 13586 1. Connect the brake pedal position sensor (2) electrical connector (1). 2. Align the brake pedal position sensor (1) with the actuation arm (2) on the brake pedal and the brake pedal position sensor mounting bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Description and Operation > Page 13587 3. Notice: Refer to Fastener Notice in Service Precautions. Install a new 4 mm bolt (1), with LOCTITETM , to the brake pedal position sensor. ^ Tighten the bolt to 9 Nm (80 inch lbs.). 4. Calibrate the brake pedal position sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Audio Amplifier C1 - With RPO Code UQ7, Without RPO Code Y91 Amplifier: Diagrams Audio Amplifier C1 - With RPO Code UQ7, Without RPO Code Y91 Audio Amplifier C1 - With RPO Code UQ7, Without RPO Code Y91 - Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Audio Amplifier C1 - With RPO Code UQ7, Without RPO Code Y91 > Page 13593 Audio Amplifier C1 - With RPO Code UQ7, Without RPO Code Y91 - Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Audio Amplifier C1 - With RPO Code UQ7, Without RPO Code Y91 > Page 13594 Audio Amplifier C1 - With RPO Code UQ7, Without RPO Code Y91 - Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Audio Amplifier C1 - With RPO Code UQ7, Without RPO Code Y91 > Page 13595 Amplifier: Diagrams Audio Amplifier C1 - With RPO Code UQ7,Y91 Audio Amplifier C1 - With RPO Code UQ7,Y91 - Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Audio Amplifier C1 - With RPO Code UQ7, Without RPO Code Y91 > Page 13596 Audio Amplifier C1 - UQ7 With RPO Code Y91 - Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Audio Amplifier C1 - With RPO Code UQ7, Without RPO Code Y91 > Page 13597 Audio Amplifier C1 - With RPO Code UQ7,Y91 - Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Audio Amplifier C1 - With RPO Code UQ7, Without RPO Code Y91 > Page 13598 Amplifier: Diagrams Audio Amplifier C2 - With RPO Code UQ7 Without RPO Code Y91 Audio Amplifier C2 - With RPO Code UQ7 Without RPO Code Y91 - Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Audio Amplifier C1 - With RPO Code UQ7, Without RPO Code Y91 > Page 13599 Audio Amplifier C2 - With RPO Code UQ7 Without RPO Code Y91 - Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Audio Amplifier C1 - With RPO Code UQ7, Without RPO Code Y91 > Page 13600 Amplifier: Diagrams Audio Amplifier C2 - With RPO Code UQ7,Y91 Audio Amplifier C2 - With RPO Code UQ7,Y91 - Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Audio Amplifier C1 - With RPO Code UQ7, Without RPO Code Y91 > Page 13601 Audio Amplifier C2 - With RPO Code UQ7, Y91 - Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Audio Amplifier Amplifier: Description and Operation Audio Amplifier AUDIO AMPLIFIER The audio amplifier is standard on some vehicle lines but is optional on most. The radio supplies low level audio signals to the audio amplifier in order to boost the signal sent to the speakers. The class 2 signal circuit allows the radio to recognize that an amplifier is present. Once the radio detects an audio amplifier, it will output low level audio signals. The audio amplifier is turned on when it receives a message via the class 2 serial data circuit indicating that the radio is on. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Audio Amplifier > Page 13604 Amplifier: Description and Operation Amplifier AMPLIFIER The amplifier in early build vehicles is a class 2 device that communicates with the scan tool on the Class 2 bus. The Class 2 amplifier will set a U100 in the radio if there is a communication problem. The late build vehicles have a NON-Class 2 amplifier that does not communicate over the Class 2 bus and therefore the NON-Class 2 amplifier will not set codes. Both amplifiers have similar operating characteristics, therefore, there are not separate diagnostics for the NON-Class 2 amplifier. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Page 13605 Amplifier: Service and Repair AMPLIFIER REPLACEMENT REMOVAL PROCEDURE 1. If equipped with a Bose. amplifier, remove the radio amp fuse located under the hood electrical center. 2. Remove the floor console bezel. 3. Remove the cupholder. 4. Remove the bolts (1) retaining the console to the instrument panel (I/P). 5. Remove the console storage bin. 6. Remove the center console end panel. 7. Disconnect the audio amplifier electrical connectors. 8. Remove the 4 screws retaining the upper console bracket to the lower console bracket. The front 2 screws (1) are shown in the graphic. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Page 13606 9. Move both front seats to the fully forward. 10. Reposition the inboard seat track trim (1) in order to gain access to the rear console side panel screw (2). 11. Remove both rear console side panel screws. 12. Move both front seats to the fully rearward. 13. Remove both front console side panel screws (1). 14. Disconnect the floor console electrical connector. 15. Remove the console assembly from the vehicle. 16. Remove the audio amplifier screws (1). 17. Remove the audio amplifier from the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Page 13607 INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the audio amplifier to the floor console lower bracket. 2. Install the amplifier screws. Tighten Tighten the screws to 3.4 N.m (30 lb in). 3. Install the floor console. 4. Connect the floor console electrical connector. 5. Install the screws (1) that retaining the upper console bracket to the lower console bracket. Tighten Tighten the retaining screws to 2 N.m (18 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Page 13608 6. Install the bolts (1) retaining the console to the I/P. Tighten Tighten the bolts to 4 N.m (35 lb in). 7. Install both front console side panel screws (1). Tighten Tighten the screws to 2 N.m (18 lb in). 8. Move both front seats to the fully forward. 9. Install both rear console side panel screws (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Page 13609 Tighten Tighten the retaining screws to 2 N.m (18 lb in). 10. Reposition the inboard seat track trim (1). 11. Connect the audio amplifier electrical connectors. 12. Connect the floor console electrical connector. 13. Install the center console end panel. 14. Install the console storage bin. 15. Install the cupholder to the console. 16. Install the upper console bezel. 17. Install the radio amp fuse. 18. If the amplifier has been replaced, perform the audio amplifier set up procedure for the BOSE. amplifier with UQ7 and Y91. Refer to Audio Amplifier Setup. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Description and Operation CD Changer: Description and Operation REMOTE CD CHANGER (CDX) The remote CD changer allows for multiple compact disks to be played continuously without having to manually change compact discs. Normal size discs may be played using the slots supplied in the magazine. The magazine must first be loaded with discs before it can played. To load CDs, insert the CDs from bottom to top, placing the discs in the magazine label side up. If a disc is loaded label side down, the disc will not play and an error will occur. Care should be used to align and insert the disc into one disc tray only. Repeat this procedure for loading all of the discs in the magazine. Once the discs are loaded into the magazine, push the magazine into the changer in the direction of the arrow marked on the magazine. When the CD magazine is loaded, the changer will begin checking for discs in the magazine. This will continue for up to one and a half minutes, depending on the number of discs loaded. To eject the magazine from the player, push the CD changer door. The door will open. Then press the eject button. NOTICE: If the CD magazine fails to eject after the EJECT button has been pressed, do not attempt to pry the magazine from the CD changer. Whenever a CD magazine with discs is loaded in the changer, the CD changer symbol will appear on the radio display. If the CD changer is checking the magazine for CDs, the CD symbol will flash on the display until the changer is ready to play. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Diagrams Remote Control: Diagrams Steering Wheel Audio Controls - Left (With RPO Code YE9) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Diagrams > Page 13622 Steering Wheel Audio Controls - Right (With RPO Code YE9) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Description and Operation > Remote Control - VCP Remote Control: Description and Operation Remote Control - VCP REMOTE CONTROL To use the remote control, aim it at the infrared window below the video screen and press the desired remote control button. Direct sunlight or very bright light may affect the ability of the entertainment system to receive signals from the remote control. If the remote control does not seem to be working, the batteries may need to be replaced. Objects blocking the line of sight may affect the function of the remote control. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Description and Operation > Remote Control - VCP > Page 13625 Remote Control: Description and Operation Steering Wheel Controls STEERING WHEEL CONTROLS Some audio functions are available using the steering wheel controls. The steering wheel controls consist of multiple momentary contact switches that connect a series of resistors. When a steering wheel control button is pressed, a specific resistance value is noted by the body control module (BCM). This results in a generated voltage, unique to the particular button. The BCM alerts the radio that the button has been pressed, and the radio responds, just as if the corresponding radio front panel button had been pressed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door Speaker: Diagrams Speaker - LF Door Speaker - LF Door - With RPO Code UQ5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 13630 Speaker - LF Door - With RPO Code UQ3/UQ7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 13631 Speaker: Diagrams Speaker - LF Tweeter Speaker - LF - Tweeter - With RPO Code UQ3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 13632 Speaker - LF - Tweeter - With RPO Code UQ7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 13633 Speaker: Diagrams Speaker - LR Door Speaker - LR - Except Crew Cab Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 13634 Speaker - LR Door - Crew Cab Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 13635 Speaker: Diagrams Speaker - RF Door Speaker - RF Door - With RPO Code UQ5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 13636 Speaker - RF Door - With RPO Code UQ3/UQ7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 13637 Speaker: Diagrams Speaker - LF Door - With RPO Code UQ5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 13638 Speaker - LF Door - With RPO Code UQ3/UQ7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 13639 Speaker - LF - Tweeter - With RPO Code UQ3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 13640 Speaker - LF - Tweeter - With RPO Code UQ7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 13641 Speaker - LR - Except Crew Cab Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 13642 Speaker - LR Door - Crew Cab Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 13643 Speaker - RF Door - With RPO Code UQ5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 13644 Speaker - RF Door - With RPO Code UQ3/UQ7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 13645 Speaker - RF - Tweeter - With RPO Code UQ3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 13646 Speaker - RF - Tweeter - With RPO Code UQ7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 13647 Speaker - RR - Except Crew Cab Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 13648 Speaker - RR Door - Crew Cab Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF Door > Page 13649 Speaker - Subwoofer With RPO Code UQ7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console Speaker: Service and Repair Speaker Replacement - Front Floor Console SPEAKER REPLACEMENT - FRONT FLOOR CONSOLE (SUBWOOFER SPEAKER) REMOVAL PROCEDURE 1. Remove the 2 front seats. 2. Move the center console rearward slightly in order to disconnect the wire connector. 3. Move the console rearward to gain access to the subwoofer speaker. 4. Remove the 4 retaining bolts from the speaker. 5. Disconnect the wire connector. 6. Remove the speaker from the subwoofer assembly. INSTALLATION PROCEDURE 1. Install the speaker into the subwoofer assembly. 2. Connect the wire connector. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the 4 retaining screws. Ensure the screw follows the same thread in the screw boss so that a new thread is not formed. Tighten Tighten the screws to 6 N.m (53 lb in). 4. Move the console forward in order to connect the wire connector. 5. Install the console to the I/P. 6. Install the 2 front seats. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console > Page 13652 Speaker: Service and Repair Speaker Replacement - Front SPEAKER REPLACEMENT - FRONT (WINDSHIELD PILLAR SPEAKER) REMOVAL PROCEDURE 1. Remove the windshield garnish molding (2). 2. Disconnect the electrical connector (3) to the speaker. 3. Remove the speaker (1) by press until it is out of the molding. INSTALLATION PROCEDURE 1. Press in the speaker (1) until it is fully seated. 2. Connect the electrical connector (3). 3. Install the windshield garnish molding (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console > Page 13653 Speaker Replacement Reference Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console > Page 13654 Speaker: Service and Repair Speaker Replacement - Front Door SPEAKER REPLACEMENT - FRONT DOOR REMOVAL PROCEDURE 1. Remove the trim panel. 2. Remove the speaker by pushing down on the top retainer. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the speaker. Snap the speaker into place and ensure that the speaker is fully seated. 3. Install the trim panel. 4. Inspect the component's operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console > Page 13655 Speaker: Service and Repair Speaker Replacement - Front Floor Console SPEAKER REPLACEMENT - FRONT FLOOR CONSOLE (SUBWOOFER SPEAKER) REMOVAL PROCEDURE 1. Remove the 2 front seats. 2. Move the center console rearward slightly in order to disconnect the wire connector. 3. Move the console rearward to gain access to the subwoofer speaker. 4. Remove the 4 retaining bolts from the speaker. 5. Disconnect the wire connector. 6. Remove the speaker from the subwoofer assembly. INSTALLATION PROCEDURE 1. Install the speaker into the subwoofer assembly. 2. Connect the wire connector. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the 4 retaining screws. Ensure the screw follows the same thread in the screw boss so that a new thread is not formed. Tighten Tighten the screws to 6 N.m (53 lb in). 4. Move the console forward in order to connect the wire connector. 5. Install the console to the I/P. 6. Install the 2 front seats. Speaker Replacement - Front SPEAKER REPLACEMENT - FRONT (WINDSHIELD PILLAR SPEAKER) REMOVAL PROCEDURE 1. Remove the windshield garnish molding (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console > Page 13656 2. Disconnect the electrical connector (3) to the speaker. 3. Remove the speaker (1) by press until it is out of the molding. INSTALLATION PROCEDURE 1. Press in the speaker (1) until it is fully seated. 2. Connect the electrical connector (3). 3. Install the windshield garnish molding (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console > Page 13657 Speaker Replacement Reference Speaker Replacement - Front Door SPEAKER REPLACEMENT - FRONT DOOR REMOVAL PROCEDURE 1. Remove the trim panel. 2. Remove the speaker by pushing down on the top retainer. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console > Page 13658 1. Connect the electrical connector. 2. Install the speaker. Snap the speaker into place and ensure that the speaker is fully seated. 3. Install the trim panel. 4. Inspect the component's operation. Speaker Replacement - Rear Pillar SPEAKER REPLACEMENT - REAR PILLAR REMOVAL PROCEDURE 1. Remove the trim panel. 2. Remove the speaker by pushing down on the top retainer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console > Page 13659 3. Disconnect the electrical connector and remove the speaker. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the speaker by snapping the top retainer into place. 3. Install the trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console > Page 13660 Verify the component's operation. Speaker Replacement - Rear Door (Crew Cab) SPEAKER REPLACEMENT - REAR DOOR (CREW CAB) REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the screws (1) retaining the speaker to the mounting bracket. 3. Disconnect the electrical connector from the speaker. 4. Remove the speaker from the mounting bracket. 5. Remove the bolts (2) retaining the speaker mounting bracket to the door, if required. 6. Remove the speaker mounting bracket. INSTALLATION PROCEDURE 1. Install the speaker mounting bracket. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolts (2) retaining the speaker mounting bracket to the door, if removed. Tighten Tighten the bolts to 6 N.m (53 lb in). 3. Install the speaker to the mounting bracket. 4. Connect the electrical connector to the speaker. 5. Install the screws (1) that retain the speaker to the mounting bracket. Tighten Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Floor Console > Page 13661 Tighten the screws to 2 N.m (53 lb in). 6. Install the door trim panel. 7. Verify the component operation. Speaker Replacement - Rear Door (Extended Cab) SPEAKER REPLACEMENT - REAR DOOR (EXTENDED CAB) REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the speaker by pushing down on the retainer. 3. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Install the electrical connector. 2. Install the speaker by snapping the speaker into place. 3. Install the door trim panel. 4. Verify the component's operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Description and Operation Cassette Features Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Description and Operation Accessory Delay Module: Description and Operation RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION SERIAL DATA CONTROL OF RETAINED ACCESSORY POWER (RAP) The class 2 modules receive the power mode message from the body control module (BCM) over the serial data circuits, indicating when the RAP power mode is current. The BCM monitors the ignition switch position, battery condition and passenger compartment doors status to determine whether RAP should be initiated. The modules then support the operation of the systems under their control as required by their RAP power mode operation. RAP will end when one of the following conditions is met: The BCM receives an input indicating the opening of any compartment door. - The BCM internal timer for the RAP expires after approximately 10 minutes. - The BCM detects a decrease in battery capacity below a prescribed limit. The BCM then sends a serial data power mode message Off-Awake ending the RAP function. The class 2 RAP functions are: The power windows - The radio Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accessory Delay Module: Initial Inspection and Diagnostic Overview Diagnostic Starting Point DIAGNOSTIC STARTING POINT Begin the system diagnosis with the Diagnostic System Check - Accessory Delay Module. The diagnostic system check will provide the following information: - The identification of the control modules which command the system - The ability of the control modules to communicate through the serial data circuit - The identification of any stored diagnostic trouble codes DTCs and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check DIAGNOSTIC SYSTEM CHECK TEST DESCRIPTION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 13671 Steps 1-5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 13672 Steps 6-7 The numbers below refer to the step numbers on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 3. This step tests for valid system power moding in all ignition switch positions. 5. The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 13673 Accessory Delay Module: Symptom Related Diagnostic Procedures A Symptoms SYMPTOMS IMPORTANT: Review the system operation in order to familiarize yourself with the system functions. Refer to Retained Accessory Power (RAP) Description and Operation. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the RAP feature. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: - Retained Accessory Power (RAP) On After Timeout - Retained Accessory Power (RAP) Inoperative Steps 1-3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 13674 Steps 4-5 Steps 1-5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 13675 Accessory Delay Module: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Courtesy Lamp Switch: Input showing state of the courtesy lamp as commanded by the BCM. Cargo Door Ajar Switch: Input from the liftgate and liftglass indicating their status. Driver Door Ajar Switch (w/o DDM): Input from the driver door indicating door status. Left Rear/Rear Cargo Door Ajar Switch: Input from the left rear door indicating its status. Passenger Door Ajar Switch (w/o PDM): Input from the front passenger door indicating door status. RAP Relay: Output indicates the RAP Relay state that the control module has commanded. Right Rear Door Ajar Sw.: Input from the right rear door indicating door status. BCM Data List DDM Data List PDM Data List Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 13684 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 13685 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 13686 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 13692 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 13693 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 13694 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13703 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13704 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13705 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13706 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13707 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13708 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13709 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13710 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13711 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13712 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13713 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13714 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13715 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13716 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13717 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13718 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13719 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13720 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13721 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13722 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13723 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13724 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13725 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13726 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13727 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13728 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13729 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13730 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13731 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13732 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13733 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13734 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13735 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13736 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 13742 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: Customer Interest OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED > Page 13747 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 13752 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 13757 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 13758 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 13764 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13773 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13774 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13775 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13776 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13777 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13778 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13779 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13780 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13781 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13782 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13783 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13784 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13785 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13786 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13787 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13788 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13789 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13790 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13791 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13792 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13793 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13794 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13795 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13796 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13797 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13798 Circuit/System Testing Component Testing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13803 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13804 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13805 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13806 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13807 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13808 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13809 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13810 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13811 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13812 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13813 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13814 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13815 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13816 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13817 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13818 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13819 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13820 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13821 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13822 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13823 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13824 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13825 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13826 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13827 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13828 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13829 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13830 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13831 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13832 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13833 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13834 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13835 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 13836 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13841 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13842 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13843 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13844 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13845 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13846 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13847 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13848 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13849 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13850 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13851 Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13852 Labor Time Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 13857 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: All Technical Service Bulletins OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED > Page 13866 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 13875 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 13880 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 13881 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 13887 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13896 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13897 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13898 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13899 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13900 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13901 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13902 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13903 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13904 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13905 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13906 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13907 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13908 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13909 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13910 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13911 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13912 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13913 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13914 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13915 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13916 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13917 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13918 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13919 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13920 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13921 Circuit/System Testing Component Testing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13926 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13927 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13928 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13929 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13930 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13931 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13932 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13933 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13934 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13935 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13936 Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 13937 Labor Time Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 13942 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: All Technical Service Bulletins OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED > Page 13951 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 13960 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 13965 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 13966 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13976 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13977 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13978 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13979 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13980 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13981 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13982 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13983 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13984 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13985 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13986 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13987 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13988 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13989 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13990 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13991 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13992 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13993 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13994 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13995 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13996 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13997 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13998 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 13999 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14000 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 14001 Circuit/System Testing Component Testing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14006 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14007 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14008 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14009 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14010 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14011 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14012 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14013 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14014 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14015 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14016 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14017 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14018 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14019 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14020 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14021 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14022 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14023 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14024 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14025 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14026 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14027 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14028 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14029 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14030 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14031 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14032 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14033 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14034 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14035 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14036 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14037 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14038 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 14039 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14044 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14045 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14046 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14047 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14048 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14049 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14050 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14051 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14052 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14053 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14054 Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 14055 Labor Time Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 14060 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Service and Repair Global Positioning System Module: Service and Repair COMMUNICATION INTERFACE MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The vehicle communication interface module (VCIM) has a specific set of unique numbers that tie the module to each vehicle. These numbers, the 10-digit station identification (STID) and the 11-digit electronic serial number (ESN), are used by the National Cellular Network and Onstar(R) to identify the specific vehicle. Because these numbers are tied to the vehicle identification number of the vehicle, you must never exchange these parts with those of another vehicle. 1. Remove the instrument panel (I/P) top trim panel. 2. Disconnect the wire connectors (2) from the module. 3. Disconnect the coaxial cable (3) from the module. 4. Remove the nuts (2) retaining the module to the bracket. 5. Remove the module (3) from the vehicle. INSTALLATION PROCEDURE 1. If replacing the VCIM, record the 10-digit STID number, and the 11-digit ESN number from the labels on the new module. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Service and Repair > Page 14072 2. Install the module on the bracket. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the retaining nuts (2). Tighten Tighten the nuts to 1.6 N.m (14 lb in). 4. Connect the coaxial cable (3) to the module. 5. Connect the wire connectors (2) to the module. 6. Install the I/P trim panel. IMPORTANT: After replacing the vehicle communication interface module, you must reconfigure the Onstar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. In addition, pressing and holding the white dot button on the keypad will NOT reset this version of the Onstar(R) system. This action will cause a DTC to set. 7. Reconfigure the Onstar(R) system. Refer to OnStar Reconfiguration. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 04-08-52-005 > Jun > 04 > Keyless Entry - Inoperative Keyless Entry Module: Customer Interest Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Module: > 04-08-52-005 > Jun > 04 > Keyless Entry - Inoperative > Page 14081 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 04-08-52-005 > Jun > 04 > Keyless Entry - Inoperative Keyless Entry Module: All Technical Service Bulletins Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Module: > 04-08-52-005 > Jun > 04 > Keyless Entry - Inoperative > Page 14087 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14096 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14097 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14098 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14104 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14105 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14106 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 14111 Passlock Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 14112 Lock Cylinder Switch: Description and Operation PASSLOCK(TM) SENSOR The Passlock(TM) sensor is inside the ignition cylinder lock housing. The Passlock(TM) sensor contains 2 hall effect sensors. The tamper hall effect sensor is on the top. The security hall effect sensor is under the tamper hall effect sensor. Both of the hall effect sensors monitor the magnet of the lock cylinder through an opening. The tamper hall effect sensor is physically placed on top of the security hall effect sensor. This arrangement enables the tamper hall effect sensor to engage first if an intruder attempts to bypass the Passlock(TM) sensor by placing a large magnet around that area of the steering column. There is a tamper resistor inside the Passlock(TM) sensor in order to help prevent tamper to the system. Passlock(TM) equipped vehicles have a selection of 10 different security resistors ranging from 0.5K ohms up to 13.6K ohms. Installing one of the security resistors inside the Passlock(TM) sensor will generate a unique Passlock(TM) code. All 10 combinations of the Passlock(TM) sensor have the same part number. However, you cannot simply replace the Passlock(TM) sensor and expect the system to operate properly. Always start by performing the Diagnostic System Check first and following the instructions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Description and Operation Pedal Positioning Switch: Description and Operation Brake Pedal Position Sensor Calibration Description and Operation Calibration Criteria The brake pedal position (BPP) sensor receives a low reference signal and a 5-volt reference signal from the electro-hydraulic power steering (EHPS). Whenever the brake pedal is applied, the brake pedal position sensor applies a variable voltage signal to the EHPS through the BPP sensor signal circuit. Brake pedal position sensor calibration must be performed after the brake pedal position sensor or EHPS system have been serviced. The calibration procedure will set brake pedal position sensor home value. This value is used by the EHPS to determine the brake pedal position and the brake pedal rate. These two outputs are provided to the hybrid control module (HCM) via GMLAN. Calibration Procedure 1. Install a scan tool. 2. Turn ON the ignition, with the engine OFF. 3. Important: Make sure the brake pedal is not depressed before sending BPP sensor calibration command. Navigate to the Special Functions screen on the scan tool and select BPP Sensor Calibration in order to perform the brake pedal position sensor calibration. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Description and Operation > Page 14116 Pedal Positioning Switch: Service and Repair Brake Pedal Position Sensor Replacement Removal Procedure 1. Important: Once the Brake Pedal Position Sensor bolt is removed for any reason, a new 4 mm bolt, with fresh LOCTITETM will need to be installed. Remove the brake pedal position sensor bolt (1). 2. Remove the brake pedal position sensor (2) from the mounting bracket. 3. Disconnect the brake pedal position sensor electrical connector (1). 4. Remove the brake pedal position sensor (2) from the vehicle Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Description and Operation > Page 14117 1. Connect the brake pedal position sensor (2) electrical connector (1). 2. Align the brake pedal position sensor (1) with the actuation arm (2) on the brake pedal and the brake pedal position sensor mounting bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Description and Operation > Page 14118 3. Notice: Refer to Fastener Notice in Service Precautions. Install a new 4 mm bolt (1), with LOCTITETM , to the brake pedal position sensor. ^ Tighten the bolt to 9 Nm (80 inch lbs.). 4. Calibrate the brake pedal position sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions Steering Mounted Controls Transmitter: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14127 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14128 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14129 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14130 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14131 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14132 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14133 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14134 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14135 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14136 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14137 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14138 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14139 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14140 Steering Mounted Controls Transmitter: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14141 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14142 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14143 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14144 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14145 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14146 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14147 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14148 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14149 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14150 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14151 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14152 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14153 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14154 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14155 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14156 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14157 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14158 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14159 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14160 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14161 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14162 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14163 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14164 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14165 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14166 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14167 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14168 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14169 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14170 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14171 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14172 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14173 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14174 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14175 Steering Mounted Controls Transmitter: Connector Views Steering Wheel Driver Information Center (DIC) Controls - Left (With RPO Code YE9) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14176 Steering Wheel Driver Information Center (DIC) Controls - Right (With RPO Code YE9) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14177 Steering Mounted Controls Transmitter: Electrical Diagrams Steering Wheel Controls Diagram Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Page 14178 Steering Mounted Controls Transmitter: Service and Repair Steering Wheel Control Switch Assembly Replacement Removal Procedure 1. Remove the steering wheel. 2. Remove the shroud retaining screws from the back of the steering wheel. 3. Remove the shroud from the steering wheel. 4. Position a blunt ended tool into the wire harness cavity (1) and apply moderate pressure in order to partially remove the steering wheel control switch from the steering wheel. 5. Disconnect the steering wheel control switch electrical connector. 6. Important: The bulbs in the steering wheel control switches are not serviceable. The switches should be replaced only as an assembly. Remove the steering wheel control switch from the steering wheel. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Page 14179 1. Position the steering wheel control switch to the steering wheel. 2. Connect the electrical connector to the steering wheel control switch. 3. Install the steering wheel control switch into the steering wheel, ensuring the retaining tabs are fully seated. 4. Install the shroud to the steering wheel. 5. Notice: Refer to Fastener Notice in Service Precautions. Install the shroud retaining screws to the steering wheel. ^ Tighten the screws to 2 Nm (18 inch lbs.). 6. Install the steering wheel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Hook / Bracket > Component Information > Service and Repair Towing Hook / Bracket: Service and Repair Tow Hook Replacement (25/35 Series) Removal Procedure 1. Remove the tow hook bolts from the frame rail. 2. Remove the tow hook from the vehicle. Installation Procedure 1. Install the tow hook to the frame rail. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the tow hook through the frame rail. Tighten the bolts to 85 N.m (63 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Adapter Kit > Component Information > Technical Service Bulletins > Customer Interest for Trailer Adapter Kit: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Adapter Kit: Customer Interest Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Adapter Kit > Component Information > Technical Service Bulletins > Customer Interest for Trailer Adapter Kit: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 14192 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Adapter Kit > Component Information > Technical Service Bulletins > Customer Interest for Trailer Adapter Kit: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 14193 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Adapter Kit > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Adapter Kit: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Adapter Kit: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Adapter Kit > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Adapter Kit: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 14199 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Adapter Kit > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Adapter Kit: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 14200 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams Trailer Connector: Diagrams Trailer Connector - Heavy Duty Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Page 14204 Trailer Connector - Heavy Duty Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair Trailer Hitch Replacement Removal Procedure 1. Disconnect the trailer wiring harness. 2. Remove the hitch platform bolts from the frame rails and the rear bumper. 3. Remove the hitch platform from the vehicle. Installation Procedure 1. Position the hitch platform to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the platform hitch bolts to the frame rails and the rear bumper. Tighten the bolts to 125 N.m (92 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 14208 3. Connect the trailer wiring harness. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: Customer Interest Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 14217 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 14218 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 14224 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 14225 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams Trailer Connector: Diagrams Trailer Connector - Heavy Duty Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Page 14229 Trailer Connector - Heavy Duty Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 05-02-118-002 > Feb > 05 > Steering 'Service Rear Wheel Steering' Message Body Control Module: Customer Interest Steering - 'Service Rear Wheel Steering' Message Bulletin No.: 05-02-118-002 Date: February 03, 2005 TECHNICAL Subject: DTC C0455, "Service Rear Wheel Steering", System Jumps from 4-Wheel Steer to 2-Wheel Steer (Reprogram BCM) Models: 2003-2005 Chevrolet Silverado, Suburban 2003-2005 GMC Sierra, Yukon XL with 4-Wheel Steer (RPO NYS) Condition Some customers may comment that the system will jump from 4-wheel steer to 2-wheel steer and the DIC displays the message "Service Rear Wheel Steering". Diagnosis will show DTC C0455-Front Steering Position Sensor malfunction. Cause This condition may be caused by a Class2 communication issue. Correction Reprogram the BCM. 2005 Model Year Vehicles: New software calibration, P/N 15248410, was released on TIS version 12 - broadcast to dealers on December 4, 2004. 2003-2004 Model Year Vehicles: New software calibration, P/N 15259330 ('03 Model Year) and P/N 15259331 ('04 04 Model Year), was released on TIS version 1.75 - broadcast to dealers on January 24, 2005. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 05-02-118-002 > Feb > 05 > Steering - 'Service Rear Wheel Steering' Message Body Control Module: All Technical Service Bulletins Steering - 'Service Rear Wheel Steering' Message Bulletin No.: 05-02-118-002 Date: February 03, 2005 TECHNICAL Subject: DTC C0455, "Service Rear Wheel Steering", System Jumps from 4-Wheel Steer to 2-Wheel Steer (Reprogram BCM) Models: 2003-2005 Chevrolet Silverado, Suburban 2003-2005 GMC Sierra, Yukon XL with 4-Wheel Steer (RPO NYS) Condition Some customers may comment that the system will jump from 4-wheel steer to 2-wheel steer and the DIC displays the message "Service Rear Wheel Steering". Diagnosis will show DTC C0455-Front Steering Position Sensor malfunction. Cause This condition may be caused by a Class2 communication issue. Correction Reprogram the BCM. 2005 Model Year Vehicles: New software calibration, P/N 15248410, was released on TIS version 12 - broadcast to dealers on December 4, 2004. 2003-2004 Model Year Vehicles: New software calibration, P/N 15259330 ('03 Model Year) and P/N 15259331 ('04 04 Model Year), was released on TIS version 1.75 - broadcast to dealers on January 24, 2005. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 14245 Body Control Module: Locations Body Control Module (BCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 14246 Body Control Module (BCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14249 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14250 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14251 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14252 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14253 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14254 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14255 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14256 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14257 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14258 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14259 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14260 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14261 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14262 Body Control Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14263 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14264 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14265 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14266 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14267 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14268 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14269 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14270 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14271 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14272 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14273 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14274 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14275 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14276 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14277 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14278 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14279 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14280 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14281 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14282 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14283 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14284 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14285 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14286 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14287 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14288 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14289 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14290 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14291 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14292 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14293 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14294 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14295 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14296 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14297 Body Control Module: Connector Views Body Control Module (BCM) - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14298 Body Control Module (BCM) - C2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14299 Body Control Module (BCM) - C2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14300 Body Control Module (BCM) - C2 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14301 Body Control Module (BCM) - C3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14302 Body Control Module (BCM) - C3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14303 Body Control Module (BCM) - C4 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14304 Body Control Module (BCM) - C4 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14305 Body Control Module (BCM) - C5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14306 Body Control Module (BCM) - C6 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14307 Body Control Module (BCM) - C6 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14308 Body Control Module: Electrical Diagrams Door Control Module Diagram 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14309 Door Control Module Diagram 2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14310 Door Control Module Diagram 2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14311 Door Control Module Diagram 3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14312 Door Control Module Diagram 3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Page 14313 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The body control module (BCM) monitors several inputs in order to arm and disarm the CTD system. The BCM controls the alarm function outputs. When the BCM detects an unauthorized entry (any door opened), the BCM applies ground to the horn, the park lamp and the headlamp relays. The BCM will send messages to the security telltale in the instrument cluster through the Class 2 serial data link. The BCM has the following 8 basic modes for operating the CTD system. The more detailed descriptions are below. - Off state - Idle state - Disarmed state - Ready-to-arm state - Arm initiated state - Arm delay state - Armed state - Alarm state The BCM has the following 6 discrete inputs in order to monitor the CTD system: - Ignition 1 - Driver door latch (door jamb) switch - Passenger door latch (door jamb) switch - Door lock relay - Door key switch - Passenger door unlock relay The BCM applies ground once per second for approximately 2 minutes, or until a valid input to disarm the system is received by the BCM. The Body Control Module (BCM) contains the theft deterrent system logic. The BCM reads the Passlock(TM) data from the Passlock(TM) sensor. If the Passlock(TM) data is correct, the BCM will pass theft. The BCM will then transmit the fuel continue password to the VCM/PCM. During the tamper mode the vehicle may start. The vehicle will then stall. If the BCM receives the wrong Passlock(TM) data, the VTD will immediately go into the tamper mode. The tamper mode will lock-out the vehicle fuel injectors for 10 minutes. The SECURITY indicator will flash while the VTD is in the tamper mode. If the Passlock(TM) sensor sends a correct password to the BCM when the ignition is in the ON position, the BCM will send a fuel enable signal to the VCM/PCM. The VCM/PCM will not disable the fuel due to any BCM message for the remainder of the ignition cycle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION The procedures below are designed to set-up the body control module (BCM) correctly during BCM related service. Before you start, read these procedures carefully and completely. IMPORTANT: The following procedures must be followed: 1. Programming the BCM. 2. Programming Theft Deterrent System Components, if equipped with Passlock System. PROGRAMMING THE BCM IMPORTANT: After the procedure is completed, the personalization settings of the BCM are set to a default setting. Inform the customer that the personalization must be set again. Perform the BCM special function Request BCM Info. for service programming system (SPS), then follow the SPS instructions. Refer to Service Programming System (SPS) in Programming. PROGRAMMING THEFT DETERRENT SYSTEM COMPONENTS IMPORTANT: This procedure has to be performed only for vehicles equipped with Passlock System. Perform the Programming Theft Deterrent System Components in Theft Deterrent after successfully finishing the Setup New BCM procedure. If the Programming Theft Deterrent System Components in the Theft Deterrent procedure is not performed after a BCM replacement, one of the following conditions will occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank or start. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON, with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 14316 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable(s). 2. Remove the knee bolster. 3. Disconnect the brown connector. 4. Disconnect all other connectors (1). 5. Remove the BCM from the sliding bracket. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 14317 1. Slide the BCM onto the bracket. 2. Connect all the connectors (1) except the brown connector. 3. Connect the brown connector. 4. Install the knee bolster. 5. Connect the negative battery cable(s). 6. Reprogram the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. 7. Perform the Passlock Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Pad Replacement Auxiliary Step / Running Board: Service and Repair Assist Step Pad Replacement Assist Step Pad Replacement Removal Procedure 1. Remove assist step pad bolts. 2. Remove assist step pad. Installation Procedure 1. Install assist step pad. 2. Install assist step pad bolts. Torque bolts until fully seated but not stripped. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Pad Replacement > Page 14322 Auxiliary Step / Running Board: Service and Repair Assist Step Replacement (Body Mount) Assist Step Replacement (Body Mount) Removal Procedure 1. Remove the following components from the vehicle: 1. The center body mount bolt (1) 2. The lock washer 3. The washer 2. Remove the center lower body-cushion assemblies (4). 3. Remove the following components from the assist step: 1. The center bolt (2) 2. The lock washer 3. The washer 4. Remove the assist step center bracket (5). 5. With an assistant, remove the following front components, and rear components: 1. The body mount bolts (1) 2. The lock washers (2) 3. The washers (3) 6. With an assistant, remove the assist step assembly from the vehicle. 7. Remove the lower body-mount cushion assemblies (4), front and rear, from the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Pad Replacement > Page 14323 8. Remove the following components from the front assist step brackets, and from the rear assist step brackets: 1. The bolts (1) 2. The lock washers (2) 3. The washers (3) 9. Remove the front brackets, and the rear brackets (4) from the assist step. 10. Remove the front gaskets, and the rear gaskets (5) from the assist step. Installation Procedure Important: Apply thread locker GM P/N 12345382 to all bolt threads prior to assembly. 1. Install the front gaskets, and the rear gaskets (5) to the assist step. 2. Install the front brackets, and the rear brackets (4) to the assist step. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the following components to the front assist step bracket, and the rear assist step bracket: 1. The washers (3) 2. The lock washers (2) 3. The bolts (1) Torque the bolts to 90 N.m (66 lb ft). 4. Install the lower body-mount cushion assemblies (4), front and rear, to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Pad Replacement > Page 14324 5. With an assistant, raise the assist step to the vehicle. 6. With an assistant, install the following front components, and rear components: 1. The washers (3) 2. The lock washers (2) 3. The body mount bolts (1) Torque the bolts to 90 N.m (66 lb ft). 7. Install (5) the assist step center bracket. 8. Install (2) the following components to the assist step: 1. The washer 2. The lock washer 3. The center bolt Torque to 45 N.m (33 lb ft). 9. Install (1) the following components to the assist step: 1. The washer 2. The lock washer 3. The center body mount bolt Torque to 90 N.m (66 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Pad Replacement > Page 14325 Auxiliary Step / Running Board: Service and Repair Assist Step Replacement (Sierra Pro) Assist Step Replacement (Sierra Pro) Removal Procedure 1. With the aid of an assistant remove the following components: 1. The body mounts (1) 2. The washers 2. With an assistant, remove the assist step assembly from the vehicle. 3. Remove the lower body-mount cushion assemblies (2) from the vehicle. 4. Remove the assist step bracket bolts (1). 5. Remove the assist step brackets. Installation Procedure Important: Apply thread locker GM P/N 12345382 (Canadian P/N 10953489), to all bolt threads prior to assembly 1. Install assist step brackets. 2. Install the assist step bracket bolts (1). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Pad Replacement > Page 14326 3. Install assist step bracket nuts (2). Torque the bolts to 50 N.m (37 lb ft) 4. Install the lower body-mount cushion assemblies (2) to the vehicle. 5. With an assistant, raise the assist step to the vehicle. 6. With an assistant, install the following: 1. The washers 2. The body mount bolts (1) Torque bolts to 90 N.m (66 lb ft) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Bracket > System Information > Service and Repair Front Bumper Bracket: Service and Repair Bracket Replacement - Front Bumper (2500) 1. Remove all related panels and components. 2. Remove the damaged bumper bracket. 3. Visually inspect the frame and restore all damage to factory specifications using 3-dimensional measuring. Important: If the vehicle is equipped with tow hooks, discard original fasteners. 4. Align the replacement bracket lower bolt holes with tow hook mounting locations and install the bolts (1) supplied. 5. Align the front edge of bracket with front edge of frame and mark upper bolt locations (1) on frame. 6. Rotate the bracket forward and drill 13 mm (1/2 in) holes in frame at upper bolt locations. 7. Rotate the bracket back into position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Bracket > System Information > Service and Repair > Page 14332 Notice: Refer to Fastener Notice in Service Precautions. 8. Install the fasteners supplied. Tighten the torque bracket fasteners to 70 N.m (52 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - TPO Fascia Cleaning Prior to Painting Front Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Page 14337 Front Bumper Cover / Fascia: Service and Repair Air Deflector Replacement - Front Bumper Fascia Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Disconnect the fog lamp electrical connectors, if equipped. 3. Remove the fog lamps, if equipped. 4. Loosen the center studs of the push-pins on the air deflector with a flat-bladed screwdriver. 5. Remove the air deflector from the front bumper fascia. Installation Procedure 1. Position the air deflector onto the front bumper assembly. 2. Fasten the connection ends of the push-pins onto the front bumper deflector. 3. Install the fog lamps, if equipped. 4. Connect the fog lamp electrical connectors, if equipped. 5. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Technical Service Bulletins > Body - Polypropylene Energy Absorber Replacement Front Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Technical Service Bulletins > Page 14342 Front Bumper Reinforcement: Service and Repair Brace Replacement - Front Bumper Removal Procedure 1. Remove the brace bolt (2) from the front bumper. 2. Remove the brace bolt (3) from the outboard mounting brace plate. 3. Remove the brace (1) from the vehicle. Installation Procedure 1. Install the brace (1) to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 3 bolts that retain the brace to the bumper and the outboard brace plate. * Tighten the front bumper brace bolt (2) to 15 N.m (11 lb ft). * Tighten the front bumper outboard brace plate bolt (3) to 9 N.m (80 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - TPO Fascia Cleaning Prior to Painting Rear Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Technical Service Bulletins > Body - Polypropylene Energy Absorber Replacement Rear Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Cabin Ventilation Duct > Component Information > Service and Repair Cabin Ventilation Duct: Service and Repair Pressure Relief Valve Replacement Removal Procedure Use a flat-bladed tool to pry the pressure release valve from the cab back panel. Remove the pressure relief valve from the vehicle. Installation Procedure Align the pressure relief valve into the opening of the rear cab. Press the Pressure Relief Valve into the Cab Back Panel until the locking tabs are fully seated. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement Removal Procedure Use a flat-bladed tool to pry the pressure release valve from the cab back panel. Remove the pressure relief valve from the vehicle. Installation Procedure Align the pressure relief valve into the opening of the rear cab. Press the Pressure Relief Valve into the Cab Back Panel until the locking tabs are fully seated. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Remove the wiper arms. 2. Pull up in order to release the outboard air inlet grille panel clips. 3. Remove the attaching clips running along the edges of the center air inlet grille panel. 4. Remove the sheet metal screws on each end of the air inlet grille panel. 5. Disconnect the windshield washer hose from the nozzle underneath the center air inlet grille panel. 6. Remove the air inlet grille panel. Installation Procedure 1. Connect the windshield washer hose to the nozzle under the center air inlet grille panel. 2. Position the air inlet grille panel to the vehicle and attach the clips to the edges of the center air inlet grille panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the sheet metal screws on each end of the air inlet grille panel. Tighten the sheet metal screws to 2 N.m (18 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 14362 4. Align the outboard air inlet grille panel clips and press down in order to install. 5. Install the wiper arms. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Remote Control: Description and Operation Remote Control - VCP REMOTE CONTROL To use the remote control, aim it at the infrared window below the video screen and press the desired remote control button. Direct sunlight or very bright light may affect the ability of the entertainment system to receive signals from the remote control. If the remote control does not seem to be working, the batteries may need to be replaced. Objects blocking the line of sight may affect the function of the remote control. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Door Handle Replacement Front Door Interior Handle: Service and Repair Door Handle Replacement Door Handle Replacement - Inside Removal Procedure 1. Remove the trim panel. 2. Remove the inside door handle mounting bolts. 3. Slide the inside door handle forward to release the unit from the door. 4. Disconnect the control rod from the inside door handle. 5. Remove the door handle assembly from the door. Installation Procedure 1. Connect the control rod to the inside door handle. 2. Slide the handle into place. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the inside door handle retaining bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Door Handle Replacement > Page 14374 Tighten the door handle retaining bolts to 9 N.m (80 lb in). 4. Install the trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Door Handle Replacement > Page 14375 Front Door Interior Handle: Service and Repair Door Handle Components Door Handle Bezel Replacement (Inside Side Access) Door Handle Bezel Replacement (Inside Side Access) Removal Procedure 1. Insert a flat-bladed tool at the top between the door bezel and the door panel. 2. Carefully bend outward the retaining clips while pulling out the bezel. Installation Procedure Snap the handle bezel into place in the door trim panel. Handle Bezel Replacement - Inside Handle Bezel Replacement - Inside Removal Procedure 1. Insert a flat-bladed tool between the door handle bezel and the trim panel in order to release the handle bezel tab retainers. 2. Remove the door handle bezel from the door panel. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Door Handle Replacement > Page 14376 1. Position the door handle bezel in the door trim panel. 2. Install the door handle bezel to the door panel by pressing the bezel into place until the bezel is completely seated. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Front Door Front Door Hinge: Service and Repair Door Hinge Pin and Bushing Replacement - Front Door Door Hinge Pin and Bushing Replacement - Front Door The door hinge pins and bushings are not replaceable. If the hinge pins or bushings are damaged, replace the door hinge as an assembly. Refer to Hinge Replacement - Front Door - Door Side and Hinge Replacement - Front Door - Body Side. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Front Door > Page 14381 Front Door Hinge: Service and Repair Door Hinge Replacement Door Hinge Replacement Body Side REMOVE OR DISCONNECT 1. Remove door from body. 2. Visually inspect and restore as much of the damage as possible to factory specifications. 3. Lightly hand-sand existing hinge with 100 grit or finer sandpaper to locate the four welds attaching hinge to the pillar (Fig.1.12). 4. Center punch each of the four weld marks on the original hinge. It is critical to punch the center of the weld so that as much of the weld is removed during drilling as possible. NOTE: Do not drill into the hinge pillar -drill through hinge ONLY (Fig.1.13). If necessary, use a chisel to separate the hinge from the pillar. 5. At each punch location, drill through hinge ONLY, using a 13 mm (1/2 inch) rotabroach hole saw or equivalent. (Fig.1.13). 6. Remove all remaining weld material from pillar surface to ensure a flush fit of the service hinge. INSTALL OR CONNECT 1. Repair any damage done to the pillar during drilling or removal. 2. Position the service template on the hinge pillar using 3M's Repositionable Adhesive (Part #6091), or equivalent. 3. Center punch each stud location on the hinge pillar according to the template. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Front Door > Page 14382 4. Drill 3 mm (1/8 inch) pilot hole at each center punch location. 5. Using pilot hole as guide, drill a 115 mm (29/64 inch) hole through hinge pillar at stud locations. Must be exact drill size (Fig.1.14). 6. Clean and prepare all bare metal surfaces. IMPORTANT: Prior to refinishing, refer to GM P/N 4901.M-D Refinish Manual for recommended products. 7. Apply approved anti-corrosion primer. 8. Feed fish wire (such as GM part #15017229) through hinge stud hole and out conduit hole in the pillar (Fig.1.15). 9. Install stud (part #15017230) supplied with service hinge into wire end and pull the stud into position. Draw the studs tight through the pillar using nuts (part #11516746) supplied. Remove each service nut. 10. Apply a full-bodied caulk to the entire hinge mounting surface to ensure a proper seal. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Front Door > Page 14383 11. Install hinge using nuts supplied, torque to 25 N.m (20 FT. LB.) (Fig.1.16). 12. Clean and prepare all surfaces as necessary for refinish. 13. Apply sealers and refinish as necessary. Do not combine paint systems. Refer to paint manufacturer's recommendations. 14. Install and align all related panels and components. Door Side REMOVE OR DISCONNECT 1. Remove door from body. (Refer to appropriate service manual.) 2. Visually inspect and restore as much of the damage as possible to factory specifications. 3. Lightly hand-sand existing body hinge with 100 grit or finer sandpaper to locate the four welds attaching hinge to door (Fig. 1.17). 4. Center punch each of the four weld marks on the original hinge base. It is critical to punch the center of the weld so that as much of the weld is removed during drilling as possible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Front Door > Page 14384 NOTE: Do NOT drill into the door -drill through hinge ONLY (Fig.1.18). If necessary, use a chisel to separate the hinge from door. 5. At each punch location, drill through hinge base only using a 13 mm (1/2 inch) rotabroach saw, or equivalent. (Fig.1.18) 6. Remove all remaining weld from door surface to ensure a flush fit of service hinge. INSTALL OR CONNECT 1. Repair any damage done to door during drilling or removal. 2. Clean and prepare hinge and backing plate mounting surfaces to ensure a flush fit of the service hinge. 3. Position the service template on door using 3M Repositionable Adhesive (part #6091), or equivalent. 4. Center punch each hole location on the door according to the template. 5. Drill a 3 mm (1/8 inch) pilot hole at each center punch location. 6. Using pilot hole as guide, drill a 13 mm (1/2 inch) hole through door at pilot locations (Fig.1.19). 7. Clean and prepare all surfaces, as necessary for refinish. IMPORTANT: Prior to refinishing, refer to GM P/N 4901.M-D Refinish Manual for recommended products. 8. Apply approved anti-corrosion primer. 9. Apply full-bodied caulk to the entire hinge mounting surface to ensure a proper seal. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Front Door > Page 14385 10. Align the hinge and backing plate with the holes in the door. Install bolts. Tighten bolts to 25 N.m (20 ft. lb.) (Fig.1.20). 11. Apply sealers and refinish as necessary. Do not combine paint systems. Refer to paint manufacturer's recommendations. 12. Install and align all related panels and components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Front Door > Page 14386 Front Door Hinge: Service and Repair Hinge Replacement - Front Door - Body Side Hinge Replacement - Front Door - Body Side Removal Procedure 1. Remove all of the related panels and components. 2. Remove any excess sealer surrounding the existing hinge and scribe the location of the hinge on the hinge pillar. 3. Lightly hand-sand the existing hinge with 100 grit or finer sandpaper in order to locate the 4 welds that attach the hinge to the pillar. Important: Punch the center of the weld so that as much of the weld as possible is removed during the drilling. 4. Center punch each of the four weld marks on the original hinge. Important: Do not drill into the hinge pillar. 5. Drill through the hinge base only, at each punch location. Use a 13 mm (1/2 in) rotabroach hole saw or equivalent. 6. Remove the hinge. If necessary, use a chisel in order to separate the hinge from the pillar. 7. Remove all of the remaining weld from the pillar surface in order to ensure a flush fit of the service hinge. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Front Door > Page 14387 1. Repair any damage done to the pillar during the drilling or the removal of the hinge. 2. Position the service hinge within the scribe marks on the pillar. 3. Center punch each stud location on the hinge pillar according to the service hinge. 4. Drill a 3 mm (1/8 in) (1) pilot hole at each center punch location. Important: Drill bit must be exact size. 5. Drill an 11.5 mm (29/64 in) hole at the pilot locations for the studs. 6. Clean and prepare all of the bare metal surfaces. Important: Prior to refinishing, refer to the publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 7. Apply approved anti-corrosion primer. 8. Feed fish wire (1), GM P/N 15017229 or the equivalent, through the hinge, the hinge stud hole and out of the conduit hole in the pillar 9. Install stud (2), GM P/N 15017230, supplied with the service hinge into the wire end. Pull the stud into position. 10. Hold the stud in position with the hinge and remove the fish wire. 11. Draw the stud (4) tight through the pillar. Use the nuts GM P/N 11516746 supplied. 12. Repeat steps 8-11 on the remaining stud locations. 13. Remove each service nut. 14. Apply a full-bodied caulk to the entire hinge mounting surface in order to ensure a proper seal. Notice: Refer to Fastener Notice in Service Precautions. 15. Install the hinge (2) to the pillar (3). Use the supplied nuts (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Front Door > Page 14388 Tighten the hinge nuts (4) to 25 N.m (18 lb ft). 16. Clean and prepare all of the surfaces as necessary for refinishing. 17. Apply the sealers. Refinish the surfaces as necessary. 18. Install and align all of the related panels and the components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Front Door > Page 14389 Front Door Hinge: Service and Repair Hinge Replacement - Front Door - Door Side Hinge Replacement - Front Door - Door Side Removal Procedure 1. Remove all of the related panels and components. 2. Remove any excess sealer surrounding the existing hinge and scribe the location of the hinge on the hinge pillar. 3. Lightly hand-sand the existing hinge with 100 grit or finer sandpaper in order to locate the 4 welds that attach the hinge to the door. Important: Punch the center of the weld so that as much of the weld as possible is removed during the drilling. 4. Center punch each of the four weld marks on the original hinge base. Important: Do not drill into the door (1). 5. Drill through the hinge base (2) only, at each punch location. Use a 13 mm (1/2 in) rotabroach hole saw (3) or equivalent. 6. Remove the hinge. If necessary, use a chisel in order to separate the hinge from the door. 7. Remove all of the remaining weld from the door surface in order to ensure a flush fit of the service hinge. Installation Procedure 1. Repair any damage done to the door during the drilling or the removal of the hinge. 2. Clean and prepare the backing plate mounting surfaces in order to ensure a flush fit of the backing plate. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Front Door > Page 14390 3. Position the service hinge within the scribe marks on the door. 4. Center punch each hole location on the door according to the service hinge. 5. Drill a 3 mm (1/8 in) pilot hole at each center punch location. Important: Drill bit must be exact size. 6. Drill an 11.5 mm (29/64 in) hole at the pilot locations. 7. Clean and prepare all of the bare metal surfaces. Important: Prior to refinishing, refer to the publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 8. Apply approved anti-corrosion primer. 9. Apply a full-bodied caulk to the entire hinge mounting surface in order to ensure a proper seal. Notice: Refer to Fastener Notice in Service Precautions. 10. Align the hinge (1) and the backing plate (4) with the holes in the door (2) and install the bolts (3) Tighten the bolts to 25 N.m (18 lb ft). 11. Apply the sealers. 12. Refinish the metal surfaces as necessary. 13. Install and align all of the related panels and the components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Limiter > System Information > Service and Repair Front Door Limiter: Service and Repair Door Check Link Replacement Removal Procedure 1. Fully open the door. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the body-side check strap bolt. 5. Remove the check strap plug. 6. Remove the door-side check strap nuts. 7. Pull the check strap from the inside of the door. Installation Procedure 1. Install the check strap in the door. 2. Install the check strap in the body. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the check strap nuts. Tighten the nuts to 9 N.m (80 lb in). 4. Install the check strap bolt. Tighten the bolt to 25 N.m (18 lb in). 5. Install the water deflector. 6. Install the door trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Bezel Replacement Front Door Panel: Service and Repair Bezel Replacement Handle Bezel Replacement - Inside Handle Bezel Replacement - Inside Removal Procedure 1. Insert a flat-bladed tool between the door handle bezel and the trim panel in order to release the handle bezel tab retainers. 2. Remove the door handle bezel from the door panel. Installation Procedure 1. Position the door handle bezel in the door trim panel. 2. Install the door handle bezel to the door panel by pressing the bezel into place until the bezel is completely seated. Door Handle Bezel Replacement (Inside Side Access) Door Handle Bezel Replacement (Inside Side Access) Removal Procedure 1. Insert a flat-bladed tool at the top between the door bezel and the door panel. 2. Carefully bend outward the retaining clips while pulling out the bezel. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Bezel Replacement > Page 14398 Snap the handle bezel into place in the door trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Bezel Replacement > Page 14399 Front Door Panel: Service and Repair Panel Replacement Trim Panel Replacement - Side Front Door (With YE9 Early Production) Trim Panel Replacement - Side Front Door (With YE9 Early Production) Removal Procedure 1. Remove the door handle bezel. 2. Remove the door trim panel upper extension. 3. Using a suitable flat-bladed tool, gently pry the manual lock lever from the door trim panel. 4. Remove the trim panel screws. * Remove the screw (2) from within the opening where the manual door lock lever resides. * Remove the screw (3) from the opening in front of the armrest. 5. Carefully slide the trim panel up in order to release the retainers from the door. 6. Disconnect the electrical connectors. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Bezel Replacement > Page 14400 1. Connect the electrical connectors. 2. Carefully align the panel, and slide the panel into the retainer slots in order to install the trim panel to the door. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the trim panel screws (2,3). Tighten the trim panel screws (2,3) to 2 N.m (18 lb in). 4. Install the manual lock lever to the trim panel. 1. Align the manual lock lever to the opening in the door trim panel. 2. Push inward until the manual lock lever is fully seated into the trim panel. 5. Install the door trim panel upper extension. 6. Install the door handle bezel. Trim Panel Replacement - Side Front Door (With YE9 Late Production) Trim Panel Replacement - Side Front Door (With YE9 Late Production) Removal Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Bezel Replacement > Page 14401 1. Remove the door handle bezel. 2. Remove the door trim panel upper extension. 3. Using a suitable flat-bladed tool, gently pry the manual lock lever from the door trim panel. 4. Remove the push in fastener (3) at the front edge of the door trim. 5. Remove the cap (5) covering the screw on the rear edge of the trim panel. 6. Remove the trim panel screws. * Remove the screw (2) from within the opening where the manual door lock lever resides. * Remove the screw (4) from the opening in front of the armrest. * Remove the screw (6) from the rear edge of the trim panel. 7. Carefully slide the trim panel (1) up in order to release the retainers from the door. 8. Disconnect the electrical connectors. Installation Procedure 1. Connect the electrical connectors. 2. Carefully align the trim panel (1), to the door and slide the panel into the retainer slots in order to install the trim panel to the door. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the trim panel screws (2,4,6). Tighten the trim panel screws (2,4,6) to 2 N.m (18 lb in). 4. Install the screw cover (5). 5. Install the push in fastener (3). 6. Install the manual lock lever to the trim panel. 1. Align the manual lock lever to the opening in the door trim panel. 2. Push inward until the manual lock lever is fully seated into the trim panel. 7. Install the door trim panel upper extension. 8. Install the door handle bezel. Trim Panel Replacement - Upper Extension Trim Panel Replacement - Upper Extension Removal Procedure 1. Open the front door. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Bezel Replacement > Page 14402 2. Release the upper extension by pulling outward on the front edge in order to release the upper retainer clips. 3. Remove the upper extension from the trim panel by lifting up and out. Installation Procedure 1. Position the lower retainer to the trim panel. 2. Align the upper retainer clips to the door frame. 3. Press inward on the upper extension until the clips fully engage securing the panel to the door. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Bezel Replacement > Page 14403 Front Door Panel: Service and Repair Water Deflector Replacement - Front Door Water Deflector Replacement - Front Door Removal Procedure Important: Water deflectors seal the inner panel. Water deflectors prevent water from entering into the body. A strip of adhesive between the deflector and the door secures the deflector. 1. Remove the trim panel. 2. Using a flat-blade tool, break the bond between the sealer and the door. 3. Pull the waterproof sealing tape from the deflector. 4. Remove the water deflector. Installation Procedure 1. Using waterproof tape or 3M(R) 777 (or equivalent), install the water deflector to the door. 2. Install the trim panel to the door. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair Front Door Striker: Service and Repair Striker Replacement - Door Removal Procedure Important: If both of the door striker bolts are removed at the same time, the striker backing plate will fall into the body. This will result in additional time to perform the repair. 1. Remove the lower striker bolt. 2. Loosen the upper striker bolt enough in order to rotate the striker and the spacer (if equipped) away from the lower bolt hole. 3. Install the lower striker bolt. Tighten the lower striker bolt sufficiently in order to hold the striker backing plate in place. 4. Remove the upper striker bolt. 5. Remove the spacer, if equipped. 6. Remove the striker. Installation Procedure 1. Install the striker. 2. Install the spacer, if equipped. 3. Install the upper striker bolt. 4. If the striker backing plate has moved, rotate the lower striker bolt until the upper threaded hole is properly aligned. 5. Remove the lower bolt. 6. Rotate the striker and the spacer, (if equipped) in order to align the lower threaded hole in the striker backing plate. Notice: Refer to Fastener Notice in Service Precautions. 7. Tighten the striker bolts. Tighten the door striker bolts to 24 N.m (18 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Auxiliary Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Auxiliary Weatherstrip Replacement - Auxiliary Removal Procedure 1. Open the door. 2. Pull the weather-strip from the pinchweld flange. Installation Procedure 1. Push the weather-strip over the pinch-weld flange. 2. Close the door. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Auxiliary > Page 14411 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Weatherstrip Replacement - Front Door Removal Procedure 1. Open the door. 2. Remove the sill plate. 3. Remove the hinge pillar trim panel. 4. Remove the windshield pillar molding. 5. Remove the weatherstrip from the rear side door opening. Pull the unit away from channel, separating the weatherstrip from the pinchweld flange. Installation Procedure 1. Install the weatherstrip from the rear side door opening fully seating the weatherstrip into the channel. 2. Install the windshield pillar molding. 3. Install the hinge pillar trim panel. 4. Install the sill plate. 5. Check door closing effort and seal to door fit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Auxiliary > Page 14412 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Side Door Opening Weatherstrip Replacement - Side Door Opening Removal Procedure 1. Open both doors. 2. Remove the sill plate. 3. Remove the hinge pillar trim pillar. 4. Remove the windshield pillar molding. 5. Remove the weather-strip from the rear side door pinch-weld flange. Installation Procedure 1. Install the weather-strip from the rear side door opening fully seating the weather-strip into the pinch-weld flange. 2. Install the windshield pillar molding. 3. Install the hinge pillar trim pillar. 4. Install the sill plate. 5. Inspect the door closing effort and seal to door fit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel Front Door Window Glass Weatherstrip: Service and Repair Door Window Channel Window Run Channel Replacement - Front Door Removal Procedure 1. Remove the window. 2. Remove the window glass weatherstrip. 3. Remove the window run channel bolts. 4. Remove the front and the rear window run channels from the door. Installation Procedure 1. Install the front and the rear window run channels to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the front and the rear window run channel bolts. 1. Tighten the front bolt to 9 N.m (80 lb in). 2. Tighten the rear bolt to 9 N.m (80 lb in). 3. Install the window glass weatherstrip. 4. Install the window. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 14418 Front Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Front Door Window Removal Procedure 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the window. 4. Remove the screws. 5. Pull the weatherstrip from the following locations: * The front of the glass run channel * The top of the window frame flange * The rear of the glass run channel 6. Remove the weatherstrip from the door. Installation Procedure 1. Install the weatherstrip to the following locations: * The front of the glass run channel * The top of the window frame flange * The rear of the glass run channel Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts. Tighten to 6 N.m (53 lb in). 3. Install the window. 4. Install the water deflector. 5. Install the door trim panel. 6. Inspect operation of window. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 14419 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Front Door Window Belt Outer - Front Removal Procedure Important: The outer belt sealing strip seals between the inner and outer door panels and the window at the belt line. The outer sealing strip is replaceable. Do not remove the inner sealing strip, because the strip is attached to the glass run channel. 1. Lower the window. 2. Remove the outside mirror. 3. Remove the outer sealing strip from the door, lifting up on the forward end in order to unhook the rear of the strip from the window run channel. Installation Procedure 1. Hook the rear end of the sealing strip into the window run channel. Lower and press the strip into place. 2. Install the outside mirror. 3. Raise the window. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement (Manual) Front Door Window Regulator: Service and Repair Door Window Regulator Replacement (Manual) Window Regulator Replacement - Front Door Removal Procedure 1. Raise and support the window glass. 2. Remove the trim panel. 3. Remove the water deflector. 4. Remove the 2 bolts that hold the window to the regulator. 5. Remove the bolts from the window regulator. 6. Remove the window regulator assembly from the door by folding both sides together. Installation Procedure 1. Install the regulator to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the window regulator. Tighten the bolts to 9 N.m (80 lb in). 3. Align the window glass to the regulator. 4. Install the bolts that hold the window to the regulator. Tighten the bolts to 9 N.m (80 lb in). 5. Install the water deflector. 6. Install the trim panel. 7. Lower the window. Inspect the operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement (Manual) > Page 14424 Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Motor Replacement Window Regulator Motor Replacement - Front Door Removal Procedure 1. Raise the window. If the window motor is inoperable, remove the window to gain access to the window motor retaining screws. Refer to Window Replacement - Front Door. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the door speaker. 5. Support the window. 6. Disconnect the wiring harness from the window regulator motor. 7. Remove the 3 bolts (1) from the window motor. Important: Do not allow the cable gear to come out of the housing. A failure will result with the cable coming off the spool. 8. Separate the motor from the cable housing by wiggling the window motor. Observe the orientation of the window motor. 9. Remove the motor from the door regulator assembly. Installation Procedure 1. Install the motor to the cable housing by wiggling it into place. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 3 bolts(1) to the window motor. Tighten Tighten the bolts to 5 N.m (44 lb in). 3. Install the window, if removed. 4. Connect the wiring harness to the window regulator motor. 5. Remove the window support. 6. Connect the wire connector to the switch to inspect the operation of the window. After inspection disconnect the wiring harness and continue the installation. 7. Install the speaker. 8. Install the water deflector. 9. Install the door trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Rear Door Rear Door Hinge: Service and Repair Door Hinge Pin and Bushing Replacement - Rear Door Door Hinge Pin and Bushing Replacement - Rear Door The door hinge pins and bushings are not replaceable. If the hinge pins or bushings are damaged, replace the door hinge as an assembly. Refer to Hinge Replacement - Front Door - Door Side and Hinge Replacement - Front Door - Body Side. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Rear Door > Page 14430 Rear Door Hinge: Service and Repair Hinge Replacement - Rear Door - Body Side Hinge Replacement - Rear Door - Body Side Removal Procedure 1. Remove all of the related panels and components. 2. Remove any excess sealer surrounding the existing hinge and scribe the location of the hinge on the hinge pillar. 3. Lightly hand-sand the existing hinge with 100 grit or finer sandpaper in order to locate the 4 welds that attach the hinge to the door. Important: Punch the center of the weld so that as much of the weld as possible is removed during the drilling. 4. Center punch each of the 4 weld marks on the original hinge. Important: Do not drill into the hinge pillar. 5. Drill through the hinge only at each punch location. Use a 13 mm (1/2 in) rotabroach hole saw or the equivalent. 6. Remove the hinge. If necessary, use a chisel in order to separate the hinge from the pillar. 7. Remove all of the remaining weld from the pillar surface in order to ensure a flush fit of the service hinge. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Rear Door > Page 14431 1. Repair any damage done to the pillar during the drilling or the removal. 2. Position the service hinge within the scribe marks on the pillar. 3. Center punch each stud location on the hinge pillar according to the service hinge (1). 4. Drill a 3 mm (1/8 in) pilot hole (2) at each center punch location. Important: The drill bit must be the exact size. 5. Drill an 11.5 mm (29/64 in) hole at the pilot locations for the studs. 6. Clean and prepare all of the bare metal surfaces. Important: Prior to refinishing, refer to the publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to manufacturer's recommendations. 7. Apply an approved anti-corrosion primer. 8. Feed fish wire, GM P/N 15017229 of the equivalent, through the hinge (1), the hinge stud hole and out of the conduit hole in the pillar. 9. Install the stud, GM P/N 15017230, supplied with the service hinge, into the wire end. Pull the stud into position. 10. Hold the stud in position with the hinge and remove the fish wire. 11. Draw the stud (4) tight through the pillar. Use the nuts GM P/N 11516746, supplied. 12. Repeat steps 7 through 10 on the remaining stud locations. 13. Remove each service nut. 14. Apply a full-bodied caulk to the entire hinge mounting surface in order to ensure a proper seal. 15. Install the hinge (2) to the pillar (3). Use the supplied nuts (1). Notice: Refer to Fastener Notice in Service Precautions. 16. Install the hinge (2) to the pillar (3). Use the supplied nuts (1). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Rear Door > Page 14432 Tighten the hinge nuts (4) to 25 N.m (18 lb ft). 17. Clean and prepare all of the surfaces as necessary for refinishing. 18. Apply the sealers. Refinish the surfaces as necessary. 19. Install and align all of the related panels and the components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Rear Door > Page 14433 Rear Door Hinge: Service and Repair Hinge Replacement - Rear Door - Door Side Hinge Replacement - Rear Door - Door Side Removal Procedure 1. Remove all of the related panels and components. 2. Remove any excess sealer surrounding the existing hinge and scribe the location of the hinge on the hinge pillar. 3. Lightly hand-sand the existing hinge with 100 grit or finer sandpaper in order to locate the 4 welds that attach the hinge to the pillar. Important: It is critical to punch the center of the weld so that as much of the weld as possible is removed during the drilling. 4. Center punch each of the 4 weld marks on the original hinge. Important: Do not drill into the door (1). 5. Drill through the hinge (2), at each punch location. Use a 13 mm (1/2 in) rotabroach hole saw (3) or equivalent. 6. Remove the hinge. If necessary, use a chisel in order to separate the hinge from the door. 7. Remove all of the remaining welds from the door surface in order to ensure a flush fit of the service hinge. Installation Procedure 1. Repair any damage done to the door during the drilling or the removal of the hinge. 2. Clean and prepare the backing plate mounting surfaces in order to ensure a flush fit of the backing plate. 3. Position the service hinge within the scribe marks on the door. 4. Center punch each hole location on the door according to the service hinge. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Rear Door > Page 14434 5. Drill a 3 mm (1/8 in) pilot hole at each center punch location. Important: Drill bit must be exact size. 6. Drill an 11.5 mm (29/64 in) hole at the pilot locations for the studs. 7. Clean and prepare all of the bare metal surfaces. Important: Prior to refinishing, refer to the publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 8. Apply approved anti-corrosion primer. 9. Apply a full-bodied caulk to the entire hinge mounting surface in order to ensure a proper seal. Notice: Refer to Fastener Notice in Service Precautions. 10. Align the hinge (1) and the backing plate (4) with the holes in the door (2) and install the bolts (3). Tighten the hinge to the pillar nuts to 25 N.m (18 lb ft). 11. Clean and prepare all of the surfaces as necessary for refinishing. 12. Apply the sealers. Refinish the surfaces as necessary. 13. Install and align all of the related panels and the components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Rear Door > Page 14435 Rear Door Hinge: Service and Repair Hinge Replacement - Rear Side Access Door Hinge Replacement - Rear Side Access Door Removal Procedure 1. Remove the door from the body. 2. Remove any excess sealer surrounding the hinge and scribe the location of the hinge on the body. 3. Lightly hand-sand existing body hinge with 100 grit or finer sandpaper to locate each weld attaching hinge to door. Important: Original punch marks may not necessarily indicate the center of the welds. 4. Center punch each of the 4 weld marks on the original hinge base. It is critical to punch the center of the weld so that as much of the weld is removed during drilling as possible. Important: Do not drill into the hinge pillar (3). Drill through hinge (2) only. If necessary, use a chisel to separate the hinge from pillar. 5. At each punch location, drill through hinge base only using a 13 mm (1/2 in) rotabroach hole saw (4), or equivalent. 6. Remove the hinge from the pillar (3). 7. Remove all remaining weld from the pillar surface to ensure a flush fit of service hinge. Installation Procedure 1. Repair any damage done to the pillar during drilling or removal. 2. Position the hinge within the scribe marks on the hinge pillar. 3. Center punch each stud location on the pillar according to the service hinge. 4. Drill a 3 mm (1/8 in) pilot hole at each center punch location. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Rear Door > Page 14436 5. At the pilot hole location, drill 11.5 mm (29/64 in) hole through the pillar. Important: Prior to refinishing, refer to Publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 6. Apply an approved anti-corrosion primer to all bare metal surfaces. 7. Feed fish wire GM P/N 15017229 through the hinge, the hinge pillar and out the conduit hole in the pillar. 8. Install stud GM P/N 15017230 into the end of the fish wire and pull the stud into position. 9. Hold the stud in position with the hinge and remove the fish wire. 10. Install nut GM P/N 11516746 on the stud and draw the stud through the pillar. This will seat the stud and prevent it from splitting. 11. Repeat steps 7-10 on the remaining stud locations. 12. Remove the nuts and hinge. 13. Apply a full-bodied caulk to the entire hinge mounting surface to ensure a proper seal. 14. Align the hinge and install using fasteners supplied. 15. Torque the hinge bolts to 25 N.m (18 ft lb). 16. Modify the door side hinge lower extensions (1), if installing the original access door without a door side service hinge or a used access door. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Door Hinge Pin and Bushing Replacement - Rear Door > Page 14437 17. Trim hinge extensions (1) so they maintain a wall thickness of 2 mm between the end of the extensions and the body side hinge nuts (3). 18. Measure and maintain a wall thickness of 2 mm around the hole at the end of the extension (4). Important: Prior to refinishing, refer to publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. 19. Clean and prepare all surfaces. 20. Refinish as necessary. 21. Install and align all related panels and components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Latch Replacement - Side Door Upper Rear Door Latch: Service and Repair Latch Replacement - Side Door Upper Latch Replacement - Side Door Upper Removal Procedure 1. Remove the door trim panel. 2. Remove the latch retaining bolts. 3. Disconnect the latch rod from the latch. Installation Procedure 1. Install the latch rod to the latch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the latch to the door. Tighten the bolts to 9 N.m (80 lb in). 3. Install the latch retaining bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Latch Replacement - Side Door Upper > Page 14442 4. Install the door trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Latch Replacement - Side Door Upper > Page 14443 Rear Door Latch: Service and Repair Latch Replacement - Side Door Lower Latch Replacement - Side Door Lower Removal Procedure 1. Remove the door trim panel. 2. Remove the latch retaining nuts. 3. Disconnect the latch rod from the latch. Installation Procedure 1. Install the latch rod to the latch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the latch to the door. Tighten the bolts to 9 N.m (80 lb in). 3. Install the latch retaining bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Latch Replacement - Side Door Upper > Page 14444 4. Install the door trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Service and Repair Rear Door Limiter: Service and Repair Door Check Link Replacement Removal Procedure 1. Fully open the door. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the body-side check strap bolt. 5. Remove the check strap plug. 6. Remove the door-side check strap nuts. 7. Pull the check strap from the inside of the door. Installation Procedure 1. Install the check strap in the door. 2. Install the check strap in the body. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the check strap nuts. Tighten the nuts to 9 N.m (80 lb in). 4. Install the check strap bolt. Tighten the bolt to 25 N.m (18 lb in). 5. Install the water deflector. 6. Install the door trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement Rear Door Panel: Service and Repair Panel Replacement Trim Panel Replacement - Side Access Door Trim Panel Replacement - Side Access Door Removal Procedure 1. Remove the door handle bezel. 2. Remove the screws that retain the trim panel armrest. 3. Insert a flat-bladed tool between the trim panel and the door in order to carefully pry the panel from the door. Installation Procedure 1. Install the trim panel to the door by pressing the panel edges until the panel is in place. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws that retain the trim panel armrest. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 14452 Tighten the trim panel armrest screws to 2 N.m (18 lb in). 3. Install the door handle bezel. Trim Panel Replacement - Side Rear Door (Crew Cab) Trim Panel Replacement - Side Rear Door (Crew Cab) Removal Procedure 1. Remove the door handle bezel. 2. Remove the window-regulator handle, if equipped. 3. Using a flat-bladed tool, remove the reflector lamp from the trim panel, and disconnect the electrical connector, if required. 4. Remove the manual lock lever from the trim panel using a flat-bladed tool. 5. Remove the two trim panel screws. 6. Remove the trim panel from the door by carefully sliding the panel upward then outward. 7. Disconnect the electrical connectors. Installation Procedure 1. Connect the electrical connectors, if necessary. 2. Align the retainers with the holes in the door. 3. Install the trim panel to the door by lowering the trim panel down into the retainer holes in order to seat the retainers. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the trim panel screws. Tighten the trim panel screws to 2 N.m (18 lb in). 5. Install the manual lock lever by pressing the lever until the lever is completely seated. 6. Connect the electrical connector to the reflector lamp, and install the reflector by pressing the reflector until the reflector is completely seated, if removed. 7. Install the window-regulator handle, if necessary. 8. Install the door handle bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 14453 Rear Door Panel: Service and Repair Water Deflector Water Deflector Replacement - Rear Door (Crew Cab) Water Deflector Replacement - Rear Door (Crew Cab) Removal Procedure 1. Remove the trim panel. 2. Using a flat-bladed tool, separate the bond between the sealer and the door. 3. Pull the waterproof sealing tape from the deflector. 4. Remove the water deflector. Installation Procedure 1. Position the electrical connectors through the water deflector. 2. Using waterproof tape, or 3M(R) 777, or equivalent, install the water deflector to the door. 3. Install the trim panel to the door. Water Deflector Replacement - Side Access Water Deflector Replacement - Side Access Removal Procedure Important: Water deflectors seal the inner panel. Water deflectors prevent water from entering into the body. A strip of adhesive between the deflector and the door secures the deflector. 1. Remove the trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 14454 2. Using a flat-blade tool, break the bond between the sealer and the door. 3. Pull the waterproof sealing tape from the deflectors. 4. Remove the water deflectors. Installation Procedure 1. Using waterproof tape or 3M(R) 777 (or equivalent), install the water deflectors to the door. 2. Install the trim panel to the door. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Service and Repair > Striker Replacement - Lower Rear Door Striker: Service and Repair Striker Replacement - Lower Striker Replacement - Lower Removal Procedure 1. Open the side access door. 2. Remove the lower door striker bolts. 3. Remove the lower door striker from the vehicle. Installation Procedure 1. Install the lower door striker to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the lower door striker bolts. Tighten the lower door striker bolts to 24 N.m (18 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Service and Repair > Striker Replacement - Lower > Page 14459 Rear Door Striker: Service and Repair Striker Replacement - Upper Striker Replacement - Upper Removal Procedure 1. Open the side access door. 2. Remove the upper door striker bolts. 3. Remove the upper door striker from the vehicle. Installation Procedure 1. Install the upper door striker to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the upper door striker bolts. Tighten the upper door striker bolts to 24 N.m (18 lb ft). 3. Close the door and inspect for proper operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Auxiliary Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Auxiliary Weatherstrip Replacement - Auxiliary Removal Procedure 1. Open the door. 2. Pull the weather-strip from the pinchweld flange. Installation Procedure 1. Push the weather-strip over the pinch-weld flange. 2. Close the door. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Auxiliary > Page 14464 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Side Door Opening Weatherstrip Replacement - Side Door Opening Removal Procedure 1. Open both doors. 2. Remove the sill plate. 3. Remove the hinge pillar trim pillar. 4. Remove the windshield pillar molding. 5. Remove the weather-strip from the rear side door pinch-weld flange. Installation Procedure 1. Install the weather-strip from the rear side door opening fully seating the weather-strip into the pinch-weld flange. 2. Install the windshield pillar molding. 3. Install the hinge pillar trim pillar. 4. Install the sill plate. 5. Inspect the door closing effort and seal to door fit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Auxiliary > Page 14465 Rear Door Weatherstrip: Service and Repair Rear Door Weatherstrip Replacement Weatherstrip Replacement - Rear Door Removal Procedure 1. Open the rear door. 2. Remove the rear door sill plate. 3. Remove the center pillar molding. 4. Remove the rear quarter trim panel. 5. Remove the weatherstrip (1) from the door opening flange. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Auxiliary > Page 14466 1. Install the weatherstrip (1) to the door opening flange. 2. Install the rear quarter trim panel. 3. Install the center pillar molding. 4. Install the rear door sill plate. 5. Close the rear door. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Auxiliary > Page 14467 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door Window Weatherstrip Replacement - Rear Door Window Removal Procedure 1. Remove the window. 2. Pull the weatherstrip from the front window run channel. 3. Pull the weatherstrip from the rear window run channel. 4. Pull the weatherstrip from the window frame flange. Installation Procedure 1. Align the weatherstrip in the window frame flange. 2. Press the weatherstrip into the window frame flange until fully seated. 3. Press the weatherstrip into the rear window run channel until fully seated. 4. Press the weatherstrip into the front window run channel until fully seated. 5. Install the window. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Weatherstrip Rear Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Rear Door Window Removal Procedure 1. Remove the window. 2. Pull the weatherstrip from the front window run channel. 3. Pull the weatherstrip from the rear window run channel. 4. Pull the weatherstrip from the window frame flange. Installation Procedure 1. Align the weatherstrip in the window frame flange. 2. Press the weatherstrip into the window frame flange until fully seated. 3. Press the weatherstrip into the rear window run channel until fully seated. 4. Press the weatherstrip into the front window run channel until fully seated. 5. Install the window. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Weatherstrip > Page 14473 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Rear Door Window Belt Outer Removal Procedure Important: The outer belt sealing strip seals between the inner and outer door panels and the window at the belt line. The outer sealing strip is replaceable. Do not remove the inner sealing strip, because the strip is attached to the glass run channel. 1. Lower the window. 2. Remove the outer sealing strip from the door. Installation Procedure 1. Align the sealing strip in place. Lower and press the strip into place. 2. Raise the window. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair Rear Door Window Motor: Service and Repair Window Regulator Motor Replacement - Rear Door Removal Procedure 1. Raise the window. If the window motor is inoperable, remove the window to gain access to the window motor retaining screws. Refer to Window Replacement - Rear Door. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the door speaker. 5. Support the window. 6. Disconnect the wiring harness from the window regulator motor. 7. Remove the 3 bolts from the window motor located on the front side of the motor. Important: Do not allow the cable gear come out of the housing. A failure will result with the cable coming off the spool. 8. Separate the motor from the cable housing by wiggling the window motor. Observe the orientation of the window motor. 9. Remove the motor from the window regulator assembly. Installation Procedure 1. Install the motor to the cable housing by wiggling motor into place. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 3 bolts to the window motor. Tighten the bolts to 5 N.m (44 lb in). 3. Install the window, if removed. 4. Connect the wiring harness to the window regulator motor. 5. Remove the window support. 6. Connect the wire connector to the switch to inspect the operation of the window. 7. Install the speaker. 8. Install the water deflector. 9. Install the door trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair Window Regulator Replacement - Rear Door Removal Procedure 1. Raise and support the window glass. 2. Remove the trim panel. 3. Remove the water deflector. 4. Remove the 2 bolts that hold the window to the regulator. 5. Remove the bolts from the window regulator. 6. Remove the window regulator assembly from the door by folding both sides together. Installation Procedure 1. Install the regulator to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the window regulator. Tighten the bolts to 9 N.m (80 lb in). 3. Align the window glass to the regulator. 4. Install the bolts that hold the window to the regulator. Tighten the bolts to 9 N.m (80 lb in). 5. Install the water deflector. 6. Install the trim panel. 7. Lower the window. Inspect the operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Technical Service Bulletins > Customer Interest for Fuel Door: > 05-06-04-043A > Aug > 05 > Fuel System/Body - Fuel Filler Cap Tether Too Short Fuel Door: Customer Interest Fuel System/Body - Fuel Filler Cap Tether Too Short Bulletin No.: 05-06-04-043A Date: August 02, 2005 TECHNICAL Subject: Fuel Cap Tether Too Short to Hook On Fuel Door While Fueling Vehicle (Install Fuel Filler Housing and Cap) Models: 2004-2005 Cadillac Escalade Models 2004-2005 Chevrolet Silverado, Suburban, Tahoe Models 2004-2005 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to correct the fuel filler cap P/N. P/N 15225006 is released for 2006 and 2007 model year vehicles only. The correct fuel cap for the 2004 and 2005 model year is P/N 15225005. Dealers who currently have P/N 15225006 on order (possibly back-ordered) for this concern should cancel their order and re-order P/N 15225005. Please discard Corporate Bulletin Number 05-06-04-043 (Section 06 - Engine/Propulsion System). Built Prior to the VIN Breakpoints shown. Condition Some customers may comment that the fuel cap tether is too short to hook on the fuel door while fueling the vehicle. Cause The existing fuel cap tether is too short. The existing fuel filler housing elongated hole is too small to accommodate the new fuel cap tether. Correction Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Technical Service Bulletins > Customer Interest for Fuel Door: > 05-06-04-043A > Aug > 05 > Fuel System/Body - Fuel Filler Cap Tether Too Short > Page 14488 Important: Clean the fuel filler cap and surrounding areas prior to removing the fuel filler housing in order to avoid possible contamination. 1. Remove the fuel fill cap. 2. Remove the fuel tank filler housing to fuel tank fill pipe screws. 3. Remove the fuel tank filler housing to body TORX® screws (1) and retainer (2). Important: It is NOT necessary to raise the vehicle in order to remove and/or install the fuel filler housing. 4. Remove the fuel filler housing from under the vehicle. 5. Install the new fuel filler housing, P/N 15289921, from under the vehicle. 6. Install the fuel tank filler housing to fuel tank fill pipe screws. Tighten Tighten the screws to 2.3 N.m (20 lb in). 7. Install the fuel tank filler housing to body TORX(R) screws and retainer. Tighten Tighten the screws to 2.3 N.m (20 lb in). Important: The new fuel cap, P/N 15225005 "tether strap" installs in the elongated hole in the fuel filler housing. DO NOT install the new fuel cap tether in the round hole in the fuel filler housing. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Technical Service Bulletins > Customer Interest for Fuel Door: > 05-06-04-043A > Aug > 05 > Fuel System/Body - Fuel Filler Cap Tether Too Short > Page 14489 8. Install the new fuel cap, P/N 15225005, tether strap in the elongated hole in the fuel filler housing. 9. Install the fuel fill cap on the filler pipe and tighten until the cap clicks. Parts Information Warranty Information For vehicles repaired under warranty, use the table Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Door: > 05-06-04-043A > Aug > 05 > Fuel System/Body - Fuel Filler Cap Tether Too Short Fuel Door: All Technical Service Bulletins Fuel System/Body - Fuel Filler Cap Tether Too Short Bulletin No.: 05-06-04-043A Date: August 02, 2005 TECHNICAL Subject: Fuel Cap Tether Too Short to Hook On Fuel Door While Fueling Vehicle (Install Fuel Filler Housing and Cap) Models: 2004-2005 Cadillac Escalade Models 2004-2005 Chevrolet Silverado, Suburban, Tahoe Models 2004-2005 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to correct the fuel filler cap P/N. P/N 15225006 is released for 2006 and 2007 model year vehicles only. The correct fuel cap for the 2004 and 2005 model year is P/N 15225005. Dealers who currently have P/N 15225006 on order (possibly back-ordered) for this concern should cancel their order and re-order P/N 15225005. Please discard Corporate Bulletin Number 05-06-04-043 (Section 06 - Engine/Propulsion System). Built Prior to the VIN Breakpoints shown. Condition Some customers may comment that the fuel cap tether is too short to hook on the fuel door while fueling the vehicle. Cause The existing fuel cap tether is too short. The existing fuel filler housing elongated hole is too small to accommodate the new fuel cap tether. Correction Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Door: > 05-06-04-043A > Aug > 05 > Fuel System/Body - Fuel Filler Cap Tether Too Short > Page 14495 Important: Clean the fuel filler cap and surrounding areas prior to removing the fuel filler housing in order to avoid possible contamination. 1. Remove the fuel fill cap. 2. Remove the fuel tank filler housing to fuel tank fill pipe screws. 3. Remove the fuel tank filler housing to body TORX® screws (1) and retainer (2). Important: It is NOT necessary to raise the vehicle in order to remove and/or install the fuel filler housing. 4. Remove the fuel filler housing from under the vehicle. 5. Install the new fuel filler housing, P/N 15289921, from under the vehicle. 6. Install the fuel tank filler housing to fuel tank fill pipe screws. Tighten Tighten the screws to 2.3 N.m (20 lb in). 7. Install the fuel tank filler housing to body TORX(R) screws and retainer. Tighten Tighten the screws to 2.3 N.m (20 lb in). Important: The new fuel cap, P/N 15225005 "tether strap" installs in the elongated hole in the fuel filler housing. DO NOT install the new fuel cap tether in the round hole in the fuel filler housing. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Door: > 05-06-04-043A > Aug > 05 > Fuel System/Body - Fuel Filler Cap Tether Too Short > Page 14496 8. Install the new fuel cap, P/N 15225005, tether strap in the elongated hole in the fuel filler housing. 9. Install the fuel fill cap on the filler pipe and tighten until the cap clicks. Parts Information Warranty Information For vehicles repaired under warranty, use the table Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Technical Service Bulletins > Page 14497 Fuel Door: Service and Repair Fuel Filler Door Replacement Removal Procedure 1. Open the fuel filler door. 2. Remove the screws from the fuel filler door. 3. Remove the push-pin retainer from the fuel filler door. 4. Reposition the filler neck assembly to the right. 5. Remove the screws from the fuel filler door. 6. Remove the fuel filler door. Installation Procedure 1. Position the fuel filler door to the quarter panel. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the fuel filler door. Tighten the screws to 9 N.m (80 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Technical Service Bulletins > Page 14498 3. Reposition the fuel filler neck. 4. Install the screws to the fuel filler neck. Tighten the screws to 9 N.m (80 lb in). 5. Inspect the alignment of the fuel filler door. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Technical Service Bulletins > Customer Interest for Hood Hinge: > 08-08-63-003 > Nov > 08 > Body - Replacement Fender Hood Hinge Hole Too Large Hood Hinge: Customer Interest Body - Replacement Fender Hood Hinge Hole Too Large INFORMATION Bulletin No.: 08-08-63-003 Date: November 26, 2008 Subject: Hood Hinge Pivot Hole Too Large On Some Replacement Fenders Models: 1999-2007 Chevrolet Silverado Classic 2001-2006 Chevrolet Avalanche, Suburban, Tahoe 1999-2007 GMC Sierra Classic 2001-2006 GMC Yukon Models Technicians installing GMSPO service replacement fenders may find that the fender side hood hinge pivot bolt attachment hole is too large (12 mm). The hood hinge pivot bolt attachment hole on some service fenders may be too large (12 mm), causing improper retention of the pivot bolt. To correct this condition, add a M8 X 32 mm O.D. X 2 mm thick washer between the hinge halves on the inboard side of the fender side hood hinge. This will provide the proper surface for the shoulder of the pivot bolt to contact as it is tightened. Refer to the illustration above. Parts Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Hinge: > 08-08-63-003 > Nov > 08 > Body Replacement Fender Hood Hinge Hole Too Large Hood Hinge: All Technical Service Bulletins Body - Replacement Fender Hood Hinge Hole Too Large INFORMATION Bulletin No.: 08-08-63-003 Date: November 26, 2008 Subject: Hood Hinge Pivot Hole Too Large On Some Replacement Fenders Models: 1999-2007 Chevrolet Silverado Classic 2001-2006 Chevrolet Avalanche, Suburban, Tahoe 1999-2007 GMC Sierra Classic 2001-2006 GMC Yukon Models Technicians installing GMSPO service replacement fenders may find that the fender side hood hinge pivot bolt attachment hole is too large (12 mm). The hood hinge pivot bolt attachment hole on some service fenders may be too large (12 mm), causing improper retention of the pivot bolt. To correct this condition, add a M8 X 32 mm O.D. X 2 mm thick washer between the hinge halves on the inboard side of the fender side hood hinge. This will provide the proper surface for the shoulder of the pivot bolt to contact as it is tightened. Refer to the illustration above. Parts Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Technical Service Bulletins > Page 14513 Hood Hinge: Service and Repair Hood Hinge Replacement Removal Procedure Caution: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. 1. Raise and support the hood. 2. Remove the hinge to the hood bolts. 3. Remove the hinge from the hood. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the hinge to the hood bolts. Tighten the hinge to the hood bolts to 25 N.m (18 lb ft). 2. Remove the hood support and lower hood. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Replacement Hood Latch: Service and Repair Hood Latch Replacement Hood Latch Replacement Removal Procedure 1. Raise the hood. 2. Remove the upper radiator support baffle. 3. Remove the bolts (2) from the hood release latch (1). 4. Disconnect the hood ajar indicator switch connector, if equipped. 5. Disconnect the hood release cable end from the latch. 6. Remove the hood release latch from the vehicle. Installation Procedure 1. Connect the hood release cable end to the latch. 2. Connect the hood ajar indicator switch connector, if equipped. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Replacement > Page 14518 3. Install the hood latch (1) to the radiator support (3). 4. Install the hood latch bolts (2) loosely. 5. Adjust the hood latch height so that when the hood is closed, the hood is held securely against the front hood bumpers. Notice: Refer to Fastener Notice in Service Precautions. 6. Raise the hood. Tighten the hood latch bolts to 9 N.m (80 lb in). 7. Adjust the front hood bumpers so that the top of the hood is flush with the fenders. 8. Install the upper radiator support baffle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Replacement > Page 14519 Hood Latch: Service and Repair Hood Link Replacement Hood Link Replacement Removal Procedure Caution: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. 1. Raise and support the front of the hood (1). 2. Remove the bolts (7) holding the hood link assembly to the hood hinge. 3. Remove the bolts (5) holding the hood link assembly to the fender. 4. Remove the hood link assembly from the vehicle. Installation Procedure 1. Position the hood link assembly (6) to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolt (5) holding the hood link assembly to the fender. Tighten the link assembly to the fender bolt to 25 N.m (18 lb ft). 3. Install the fender bolt (7) holding the hood link assembly to the hood hinge. Tighten the hinge bolts to 25 N.m (18 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair Hood Latch Release Cable: Service and Repair Hood Latch Release Cable Replacement Removal Procedure Important: If the cable is broken, release the hood by pressing the latch tab on the left side of the lock assembly. Use a rod to press the latch tab. 1. Lift the hood. 2. Remove the left hinge pillar trim panel. 3. Remove the electrical center cover by removing the center retaining nut, and releasing the retaining clips (1) on both sides. 4. In order to gain access to the hood release cable, it is necessary to move the electrical center by releasing the retaining clips (1) on both sides, and lifting out of the retaining grooves (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Page 14523 5. Remove the cable handle underneath the instrument panel (I/P). 6. Remove the cable end from the handle. 7. Use needle nose pliers in order to squeeze the tabs in order to remove the cable end from the hood latch assembly. 8. Lift the cable from the lock. 9. Partially remove the park brake pedal assembly to gain access to the hood release cable. Refer to Park Brake Pedal Assembly Replacement in Park Brake. 10. Pull the cable in toward the cable handle through the hole in the cowl. 11. Remove the radiator air baffle and deflector. 12. Detach the cable from the retainer clips. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Page 14524 13. Disconnect the cable end from the hood latch assembly. 14. Use needle nose pliers to squeeze the tabs in order to remove the cable end from the handle. 15. Lift the cable from the lock. Installation Procedure 1. Insert and pull the cable toward the front of the vehicle through the hole in the cowl. 2. Ensure that the grommet is seated. 3. Attach the cable end to the latch assembly. 4. Attach the cable to the retainer clips. 5. Attach the cable end to the cable handle. 6. Install the radiator air baffle and deflector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Page 14525 Notice: Refer to Fastener Notice in Service Precautions. 7. Attach the cable handle underneath the I/P. Tighten the cable handle nut to 11 N.m (97 lb in). 8. Install the park brake pedal assembly. 9. Install the electrical center by setting it into the retaining grooves (2), and securing the retaining clips (1) on both sides. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Page 14526 10. Install the electrical center cover by securing the retaining clips (1) on both sides. 11. Install the center retaining nut. Tighten the center retaining nut to 2.5 N.m (22 lb in). 12. Install the left hinge pillar trim panel. 13. Close the hood. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Stop > Component Information > Service and Repair Hood Stop: Service and Repair Hood Bumper Replacement Removal Procedure 1. Remove the front hood bumper by turning the front hood bumper (1) out counterclockwise. 2. Remove the side hood bumper by sliding the side hood bumper (2) rearward and pulling up. Installation Procedure 1. Install the side hood bumper by pushing down and sliding the side hood bumper (2) forward. 2. Install the front hood bumper (1) by turning the front hood bumper in clockwise until the hood closes flush with the fender. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair Hood Weatherstrip: Service and Repair Seal Replacement - Hood Rear Removal Procedure Pull up on the rear hood seal and remove from the cowl pinch-weld flange. Installation Procedure Align the slot in the rear hood seal with the cowl pinch-weld flange and press into place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Component Information > Specifications Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Component Information > Specifications > Page 14536 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Technical Service Bulletins > 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION Body Emblem: Technical Service Bulletins 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION TECHNICAL Bulletin No.: 06-08-111-004B Date: September 25, 2009 Subject: Information on Discoloration, Blistering, Peeling or Erosion of Various Exterior Emblems Including Chevy Bowtie (Bulletin Cancelled) Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being cancelled. Please discard Corporate Bulletin Number 06-08-111-004A (Section 08 - Body & Accessories). This bulletin is being cancelled. The information is no longer applicable. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem Replacement - Grille (Cadillac) Body Emblem: Service and Repair Emblem Replacement - Grille (Cadillac) Emblem Replacement - Grille (Cadillac) Removal Procedure 1. Mask grille in the area surrounding the emblem to prevent damage to the painted surface. 2. Remove the emblem (1) from the grille (2) using a small plastic flat-bladed tool. 3. Remove all traces of adhesive from the grille surface using an oil-free naphtha or alcohol. Installation Procedure 1. Remove the protective tape from the adhesive strip on the grille emblem (1). 2. Install the emblem (1) onto the grille (2) centering the emblem on the mating surface. 3. Remove the masking tape from the painted surface surrounding the emblem. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem Replacement - Grille (Cadillac) > Page 14544 Body Emblem: Service and Repair Emblem Replacement - Grille (Chevrolet) Emblem Replacement - Grille (Chevrolet) Removal Procedure 1. Remove the upper grille baffle. 2. Remove the retaining nuts (3) from the rear of the grille emblem (1). 3. Separate and remove the emblem (1) from the grille (2). Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem Replacement - Grille (Cadillac) > Page 14545 1. Install the emblem (1) onto the grille (2). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the retaining nuts (3) and tighten. Tighten the retaining nuts to 3 N.m (27 lb in). 3. Reinstall the upper grille baffle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem Replacement - Grille (Cadillac) > Page 14546 Body Emblem: Service and Repair Emblem/Nameplate Replacement - Door (W/O SS) Emblem/Nameplate Replacement - Door (W/O SS) Tools Required J 25070 Heat Gun Removal Procedure Important: Use the tape for protection and alignment marks for alignment of the new emblem. 1. Apply tape to the area around the door emblem. 2. Heat the emblem/nameplate, using a heat gun J 25070 152 mm (6.0 in) from the surface. 3. Apply the heat using a circular motion for about 30 seconds. Notice: Refer to Exterior Trim Emblem Removal Notice in Service Precautions. 4. Remove the emblem/nameplate from the door surface using a plastic, flat-bladed tool. 5. Remove all adhesive from the door panel surface and the back of the emblem/nameplate using 3M(TM) scotch brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. 6. Clean the door surface using varnish makers and painters (VMP) naptha. Installation Procedure 1. If the location of the emblem/nameplate has not been marked apply tape. 2. Warm the door surface with a heat gun J 25070 152 mm (6.0 in) from the surface to a minimum of 21°C (70°F). Important: Do not touch the adhesive backing of the emblem/nameplate. 3. Remove the backing from the front end of the emblem/nameplate. 4. Press the emblem/nameplate to the door panel surface while continuing to remove the backing. 5. Hand roll the emblem/nameplate to the door panel to ensure proper adhesion. 6. Inspect the emblem/nameplate for bonding. 7. Remove the tape from the area around the door emblem. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem Replacement - Grille (Cadillac) > Page 14547 Body Emblem: Service and Repair Emblem/Nameplate Replacement - Endgate (W/O SS) Emblem/Nameplate Replacement - Endgate (W/O SS) Tools Required J 25070 Heat Gun Removal Procedure Important: Use the tape for protection and alignment marks for alignment of the new emblem. 1. Apply tape to the area around the endgate emblem. 2. Heat the emblem/nameplate, using a heat gun J 25070 152 mm (6.0 in) from the surface. 3. Apply the heat using a circular motion for about 30 seconds. Notice: Refer to Exterior Trim Emblem Removal Notice in Service Precautions. 4. Remove the emblem/nameplate from the endgate surface using a plastic, flat-bladed tool. 5. Remove all adhesive from the endgate panel surface and the back of the emblem/nameplate using 3M(TM) scotch brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. 6. Clean the endgate surface using varnish makers and painters (VMP) naptha. Installation Procedure 1. If the location of the emblem/nameplate has not been marked apply tape. 2. Warm the endgate surface with a heat gun J 25070 152 mm (6.0 in) from the surface to a minimum of 21°C (70°F). Important: Do not touch the adhesive backing of the emblem/nameplate. 3. Remove the backing from the front end of the emblem/nameplate. 4. Press the emblem/nameplate to the endgate panel surface while continuing to remove the backing. 5. Hand roll the emblem/nameplate to the endgate panel to ensure proper adhesion. 6. Inspect the emblem/nameplate for bonding. 7. Remove the tape from the area around the endgate emblem. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem Replacement - Grille (Cadillac) > Page 14548 Body Emblem: Service and Repair Emblem Replacement - Grille (Cadillac) Emblem Replacement - Grille (Cadillac) Removal Procedure 1. Mask grille in the area surrounding the emblem to prevent damage to the painted surface. 2. Remove the emblem (1) from the grille (2) using a small plastic flat-bladed tool. 3. Remove all traces of adhesive from the grille surface using an oil-free naphtha or alcohol. Installation Procedure 1. Remove the protective tape from the adhesive strip on the grille emblem (1). 2. Install the emblem (1) onto the grille (2) centering the emblem on the mating surface. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem Replacement - Grille (Cadillac) > Page 14549 3. Remove the masking tape from the painted surface surrounding the emblem. Emblem Replacement - Grille (Chevrolet) Emblem Replacement - Grille (Chevrolet) Removal Procedure 1. Remove the upper grille baffle. 2. Remove the retaining nuts (3) from the rear of the grille emblem (1). 3. Separate and remove the emblem (1) from the grille (2). Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem Replacement - Grille (Cadillac) > Page 14550 1. Install the emblem (1) onto the grille (2). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the retaining nuts (3) and tighten. Tighten the retaining nuts to 3 N.m (27 lb in). 3. Reinstall the upper grille baffle. Emblem/Nameplate Replacement - Door (W/O SS) Emblem/Nameplate Replacement - Door (W/O SS) Tools Required J 25070 Heat Gun Removal Procedure Important: Use the tape for protection and alignment marks for alignment of the new emblem. 1. Apply tape to the area around the door emblem. 2. Heat the emblem/nameplate, using a heat gun J 25070 152 mm (6.0 in) from the surface. 3. Apply the heat using a circular motion for about 30 seconds. Notice: Refer to Exterior Trim Emblem Removal Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem Replacement - Grille (Cadillac) > Page 14551 4. Remove the emblem/nameplate from the door surface using a plastic, flat-bladed tool. 5. Remove all adhesive from the door panel surface and the back of the emblem/nameplate using 3M(TM) scotch brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. 6. Clean the door surface using varnish makers and painters (VMP) naptha. Installation Procedure 1. If the location of the emblem/nameplate has not been marked apply tape. 2. Warm the door surface with a heat gun J 25070 152 mm (6.0 in) from the surface to a minimum of 21°C (70°F). Important: Do not touch the adhesive backing of the emblem/nameplate. 3. Remove the backing from the front end of the emblem/nameplate. 4. Press the emblem/nameplate to the door panel surface while continuing to remove the backing. 5. Hand roll the emblem/nameplate to the door panel to ensure proper adhesion. 6. Inspect the emblem/nameplate for bonding. 7. Remove the tape from the area around the door emblem. Emblem/Nameplate Replacement - Endgate (W/O SS) Emblem/Nameplate Replacement - Endgate (W/O SS) Tools Required J 25070 Heat Gun Removal Procedure Important: Use the tape for protection and alignment marks for alignment of the new emblem. 1. Apply tape to the area around the endgate emblem. 2. Heat the emblem/nameplate, using a heat gun J 25070 152 mm (6.0 in) from the surface. 3. Apply the heat using a circular motion for about 30 seconds. Notice: Refer to Exterior Trim Emblem Removal Notice in Service Precautions. 4. Remove the emblem/nameplate from the endgate surface using a plastic, flat-bladed tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem Replacement - Grille (Cadillac) > Page 14552 5. Remove all adhesive from the endgate panel surface and the back of the emblem/nameplate using 3M(TM) scotch brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. 6. Clean the endgate surface using varnish makers and painters (VMP) naptha. Installation Procedure 1. If the location of the emblem/nameplate has not been marked apply tape. 2. Warm the endgate surface with a heat gun J 25070 152 mm (6.0 in) from the surface to a minimum of 21°C (70°F). Important: Do not touch the adhesive backing of the emblem/nameplate. 3. Remove the backing from the front end of the emblem/nameplate. 4. Press the emblem/nameplate to the endgate panel surface while continuing to remove the backing. 5. Hand roll the emblem/nameplate to the endgate panel to ensure proper adhesion. 6. Inspect the emblem/nameplate for bonding. 7. Remove the tape from the area around the endgate emblem. Emblem/Nameplate Replacement - Pickup Box Emblem/Nameplate Replacement - Pickup Box Tools Required J 25070 Heat Gun Removal Procedure Important: Use the tape for protection and alignment marks for alignment of the new emblem. 1. Apply tape to the area around the pickup box emblem. 2. Heat the emblem/nameplate, using a heat gun J 25070 152 mm (6.0 in) from the surface. 3. Apply the heat using a circular motion for about 30 seconds. Notice: Refer to Exterior Trim Emblem Removal Notice in Service Precautions. 4. Remove the emblem/nameplate from the pickup box surface using a plastic, flat-bladed tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem Replacement - Grille (Cadillac) > Page 14553 5. Remove all adhesive from the pickup box panel surface and the back of the emblem/nameplate using 3M(TM) scotch brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. 6. Clean the pickup box surface using varnish makers and painters (VMP) naptha. Installation Procedure 1. If the location of the emblem/nameplate has not been marked apply tape. 2. Warm the pickup box surface with a heat gun J 25070 152 mm (6.0 in) from the surface to a minimum of 21°C (70°F). Important: Do not touch the adhesive backing of the emblem/nameplate. 3. Remove the backing from the front end of the emblem/nameplate. 4. Press the emblem/nameplate to the pickup box panel surface while continuing to remove the backing. 5. Hand roll the emblem/nameplate to the pickup box panel to ensure proper adhesion. 6. Inspect the emblem/nameplate for bonding. 7. Remove the tape from the area around the pickup box emblem. Emblem/Nameplate Replacement - Pickup Cab Emblem/Nameplate Replacement - Pickup Cab Tools Required J 25070 Heat Gun Removal Procedure Important: Use the tape for protection and alignment marks for alignment of the new emblem. 1. Apply tape to the area around the pickup cab emblem. 2. Heat the emblem/nameplate, using a heat gun J 25070 152 mm (6.0 in) from the surface. 3. Apply the heat using a circular motion for about 30 seconds. Notice: Refer to Exterior Trim Emblem Removal Notice in Service Precautions. 4. Remove the emblem/nameplate from the pickup cab surface using a plastic, flat-bladed tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem Replacement - Grille (Cadillac) > Page 14554 5. Remove all adhesive from the pickup cab panel surface and the back of the emblem/nameplate using 3M(TM) scotch brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. 6. Clean the pickup cab surface using varnish makers and painters (VMP) naptha. Installation Procedure 1. If the location of the emblem/nameplate has not been marked apply tape, using the dimensions in the graphic. 2. Warm the pickup cab surface with a heat gun J 25070 152 mm (6.0 in) from the surface to a minimum of 21°C (70°F). Important: Do not touch the adhesive backing of the emblem/nameplate. 3. Remove the backing from the front end of the emblem/nameplate. 4. Press the emblem/nameplate to the pickup cab panel surface while continuing to remove the backing. 5. Hand roll the emblem/nameplate to the pickup cab panel to ensure proper adhesion. 6. Inspect the emblem/nameplate for bonding. 7. Remove the tape from the area around the pickup cab emblem. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Remove the wiper arms. 2. Pull up in order to release the outboard air inlet grille panel clips. 3. Remove the attaching clips running along the edges of the center air inlet grille panel. 4. Remove the sheet metal screws on each end of the air inlet grille panel. 5. Disconnect the windshield washer hose from the nozzle underneath the center air inlet grille panel. 6. Remove the air inlet grille panel. Installation Procedure 1. Connect the windshield washer hose to the nozzle under the center air inlet grille panel. 2. Position the air inlet grille panel to the vehicle and attach the clips to the edges of the center air inlet grille panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the sheet metal screws on each end of the air inlet grille panel. Tighten the sheet metal screws to 2 N.m (18 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair > Page 14558 4. Align the outboard air inlet grille panel clips and press down in order to install. 5. Install the wiper arms. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Lower Side Moulding / Trim: > 04-08-111-002B > Oct > 06 > Body - Dimple In Body Side Molding(s) Lower Side Moulding / Trim: Customer Interest Body - Dimple In Body Side Molding(s) Bulletin No.: 04-08-111-002B Date: October 26, 2006 TECHNICAL Subject: Dimple in Body Side Molding (Replace Moldings) Models: 2004 Chevrolet Avalanche without Body Hardware (RPO WBH) 2004 Chevrolet Silverado, Suburban, Tahoe with Body/Side Exterior-Molding-in-Color (RPO B85) Supercede: This bulletin is being revised to change the Warranty and add a revised parts information statement. Please discard Corporate Bulletin Number 04-08-111-002A (Section 08 - Body and Accessories). Condition Some customers may comment on a raised surface or a dimple in the exterior molded-in-color body side door moldings. This condition may be more pronounced in warmer climates. This does not apply to standard colored keyed black body side moldings. Cause Engineering has determined that this condition may be caused by a bar code label on the backside of the molding that dimples the molding. Correction Replace ALL of the exterior body side door moldings. Refer to Molding Replacement-Body Side procedure in SI. Dealer Action Please contact all customers that were told they would be called when a repair became available. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Lower Side Moulding / Trim: > 04-08-111-002B > Oct > 06 > Body - Dimple In Body Side Molding(s) > Page 14567 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Lower Side Moulding / Trim: > 04-08-111-002B > Oct > 06 > Body - Dimple In Body Side Molding(s) > Page 14568 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Lower Side Moulding / Trim: > 04-08-111-002B > Oct > 06 > Body - Dimple In Body Side Molding(s) > Page 14569 The moldings are available in factory colors; however, quantities are limited. When these quantities are exhausted, the moldings will only be available in paint to match only. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lower Side Moulding / Trim: > 04-08-111-002B > Oct > 06 > Body - Dimple In Body Side Molding(s) Lower Side Moulding / Trim: All Technical Service Bulletins Body - Dimple In Body Side Molding(s) Bulletin No.: 04-08-111-002B Date: October 26, 2006 TECHNICAL Subject: Dimple in Body Side Molding (Replace Moldings) Models: 2004 Chevrolet Avalanche without Body Hardware (RPO WBH) 2004 Chevrolet Silverado, Suburban, Tahoe with Body/Side Exterior-Molding-in-Color (RPO B85) Supercede: This bulletin is being revised to change the Warranty and add a revised parts information statement. Please discard Corporate Bulletin Number 04-08-111-002A (Section 08 - Body and Accessories). Condition Some customers may comment on a raised surface or a dimple in the exterior molded-in-color body side door moldings. This condition may be more pronounced in warmer climates. This does not apply to standard colored keyed black body side moldings. Cause Engineering has determined that this condition may be caused by a bar code label on the backside of the molding that dimples the molding. Correction Replace ALL of the exterior body side door moldings. Refer to Molding Replacement-Body Side procedure in SI. Dealer Action Please contact all customers that were told they would be called when a repair became available. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lower Side Moulding / Trim: > 04-08-111-002B > Oct > 06 > Body - Dimple In Body Side Molding(s) > Page 14575 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lower Side Moulding / Trim: > 04-08-111-002B > Oct > 06 > Body - Dimple In Body Side Molding(s) > Page 14576 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lower Side Moulding / Trim: > 04-08-111-002B > Oct > 06 > Body - Dimple In Body Side Molding(s) > Page 14577 The moldings are available in factory colors; however, quantities are limited. When these quantities are exhausted, the moldings will only be available in paint to match only. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-111-002B > Oct > 06 > Body - Dimple In Body Side Molding(s) Upper Side Moulding / Trim: Customer Interest Body - Dimple In Body Side Molding(s) Bulletin No.: 04-08-111-002B Date: October 26, 2006 TECHNICAL Subject: Dimple in Body Side Molding (Replace Moldings) Models: 2004 Chevrolet Avalanche without Body Hardware (RPO WBH) 2004 Chevrolet Silverado, Suburban, Tahoe with Body/Side Exterior-Molding-in-Color (RPO B85) Supercede: This bulletin is being revised to change the Warranty and add a revised parts information statement. Please discard Corporate Bulletin Number 04-08-111-002A (Section 08 - Body and Accessories). Condition Some customers may comment on a raised surface or a dimple in the exterior molded-in-color body side door moldings. This condition may be more pronounced in warmer climates. This does not apply to standard colored keyed black body side moldings. Cause Engineering has determined that this condition may be caused by a bar code label on the backside of the molding that dimples the molding. Correction Replace ALL of the exterior body side door moldings. Refer to Molding Replacement-Body Side procedure in SI. Dealer Action Please contact all customers that were told they would be called when a repair became available. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-111-002B > Oct > 06 > Body - Dimple In Body Side Molding(s) > Page 14586 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-111-002B > Oct > 06 > Body - Dimple In Body Side Molding(s) > Page 14587 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-111-002B > Oct > 06 > Body - Dimple In Body Side Molding(s) > Page 14588 The moldings are available in factory colors; however, quantities are limited. When these quantities are exhausted, the moldings will only be available in paint to match only. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-111-002B > Oct > 06 > Body - Dimple In Body Side Molding(s) Upper Side Moulding / Trim: All Technical Service Bulletins Body - Dimple In Body Side Molding(s) Bulletin No.: 04-08-111-002B Date: October 26, 2006 TECHNICAL Subject: Dimple in Body Side Molding (Replace Moldings) Models: 2004 Chevrolet Avalanche without Body Hardware (RPO WBH) 2004 Chevrolet Silverado, Suburban, Tahoe with Body/Side Exterior-Molding-in-Color (RPO B85) Supercede: This bulletin is being revised to change the Warranty and add a revised parts information statement. Please discard Corporate Bulletin Number 04-08-111-002A (Section 08 - Body and Accessories). Condition Some customers may comment on a raised surface or a dimple in the exterior molded-in-color body side door moldings. This condition may be more pronounced in warmer climates. This does not apply to standard colored keyed black body side moldings. Cause Engineering has determined that this condition may be caused by a bar code label on the backside of the molding that dimples the molding. Correction Replace ALL of the exterior body side door moldings. Refer to Molding Replacement-Body Side procedure in SI. Dealer Action Please contact all customers that were told they would be called when a repair became available. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-111-002B > Oct > 06 > Body - Dimple In Body Side Molding(s) > Page 14594 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-111-002B > Oct > 06 > Body - Dimple In Body Side Molding(s) > Page 14595 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-111-002B > Oct > 06 > Body - Dimple In Body Side Molding(s) > Page 14596 The moldings are available in factory colors; however, quantities are limited. When these quantities are exhausted, the moldings will only be available in paint to match only. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Technical Service Bulletins > All Other Service Bulletins for Upper Side Moulding / Trim: > 06-08-50-009F > Dec > 10 > Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Technical Service Bulletins > All Other Service Bulletins for Upper Side Moulding / Trim: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set Seat Occupant Sensor: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC B0092 Set Bulletin No.: 02-09-41-002A Date: March 24, 2004 TECHNICAL Subject: Air Bag Lamp On, Passenger Air Bag Indicator Always Reads OFF, DTC B0092 Set (Repair Passenger Presence System (PPS) Sensor Harness) Models: 2003-2004 Cadillac Escalade, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon XL with Sensor Indicator Inflatable Restraint Front Passenger/Child Presence Detector (RPO ALO) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 02-09-41-002 (Section 09 - Restraints). Condition Some customers may comment that the Air Bag Lamp is on and the Passenger Air Bag indicator always reads OFF. Upon investigation, the technician may find DTC B0092 set. Cause The cause of this condition may be a shorted Passenger Presence System (PPS) sensor wire. The PPS sensor harness is located under the front passenger seat. This harness may be pinched between the seat frame and the track/riser. Correction Locate the PPS sensor (1) and inspect the harness for proper routing. If the harness is pinched between the seat frame and the track/riser, use the procedure listed below to repair wire(s). 1. Move the front passenger seat to the full rearward and full tilt up position. 2. Loosen the seat frame to track/riser nut and remove the harness. 3. Tighten the seat frame to track/riser nut. 4. Repair any damaged wires. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Technical Service Bulletins > All Other Service Bulletins for Upper Side Moulding / Trim: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set > Page 14606 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Technical Service Bulletins > All Other Service Bulletins for Upper Side Moulding / Trim: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set > Page 14616 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Molding Replacement - Body Side (Standard Cab) Upper Side Moulding / Trim: Service and Repair Molding Replacement - Body Side (Standard Cab) Molding Replacement - Body Side (Standard Cab) Tools Required J 25070 Heat Gun Removal Procedure Important: Be careful not to scratch or chip the paint. 1. Heat the body side molding using a heat gun J 25070. Hold the heat gun approximately 152 mm (6 in) from the surface. Apply heat using a circular motion for about 30 seconds. 2. Starting from one end of the molding, peel off the body off the molding from the panel surface using a flat-bladed tool. 3. Remove all adhesive from the body panel using a 3M(TM) scotch brite molding adhesive remover disk P/N 07501 or equivalent. Installation Procedure Important: Apply the molding in an environment free of dust and dirt. Dust and dirt could come in contact with the adhesive surface and prevent proper adhesion. 1. Clean the area where the replacement molding is to be mounted. Use a suitable solvent such as flash naphtha or a mixture of 50 percent isopropyl alcohol and 50 percent water. 2. Dry the area thoroughly. 3. Warm the body panel to a temperature range of 16-41°C (60-105°F) with a heat lamp or heat gun J 25070. 4. Ensure the molding is at a minimum temperature of 16°C (60°F). If the temperature of the molding is below 16°C (60°F), warm up molding with a heat lamp or heat gun J 25070. Important: Do not touch the adhesive surface when the tape is removed. 5. Remove the protective tape. 6. Without allowing the adhesive surface to touch the body, ensure the molding is aligned. 7. Press on the molding in order to install to the body. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Molding Replacement - Body Side (Standard Cab) > Page 14619 Upper Side Moulding / Trim: Service and Repair Molding Replacement - Body Side (Extended Cab) Molding Replacement - Body Side (Extended Cab) Tools Required J 25070 Heat Gun Removal Procedure Important: Be careful not to scratch or chip the paint. 1. Heat the body side molding using a heat gun J 25070. Hold the heat gun approximately 152 mm (6 in) from the surface. Apply heat using a circular motion for about 30 seconds. 2. Starting from one end of the molding, peel off the molding from the panel surface using a flat-bladed tool. 3. Remove all adhesive from the body panel using a 3M(TM) scotch brite molding adhesive remover disk P/N 07501 or equivalent. Installation Procedure Important: Apply the molding in an environment free of dust and dirt. Dust and dirt could come in contact with the adhesive surface and prevent proper adhesion. 1. Clean the area where the replacement molding is to be mounted. Use a suitable solvent such as flash naphtha or a mixture of 50 percent isopropyl alcohol and 50 percent water. 2. Dry the area thoroughly. 3. Warm the body panel to a temperature range of 16-41°C (60-105°F) with a heat lamp or heat gun J 25070. 4. Ensure the molding is at a minimum temperature of 16°C (60°F). If the temperature of the molding is below 16°C (60°F), warm up molding with a heat lamp or heat gun J 25070. Important: Do not touch the adhesive surface when the tape is removed. 5. Remove the protective tape. 6. Without allowing the adhesive surface to touch the body, ensure the molding is aligned. 7. Press on the molding in order to install to the body. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair Windshield Moulding / Trim: Service and Repair Stationary Window Reveal Molding Repair Stationary Window Reveal Molding Repair Removal Procedure Caution: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. Important: The window reveal molding fills the cavity between the body and window. If the reveal molding is stretched or damaged, it cannot be reused and it must be replaced. 1. Lift up on the loose area of the reveal molding. 2. Clean the top edge of the window surface and the reveal molding with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint-free cloth. Installation Procedure Caution: Refer to Window Retention Caution in Service Precautions. 1. Verify all primers and urethane adhesive are within expiration dates. Important: Use care when applying the prep, clear #1, to the window. This primer dries almost instantly, and may stain the viewing area of the window if not applied evenly. 2. Use a new dauber in order to apply glass prep, clear #1, to the channel area approximately 13 mm (1/2 in) to the upper edge of the window. 3. Wipe the glass primed area immediately with a clean lint-free cloth. 4. Shake the glass primer, black #2, for at least 1 minute. 5. Use a new dauber in order to apply glass primer, black #2, to the top edge of the window. 6. Apply a small bead of urethane adhesive (2) between the window (1) and the pinch-weld. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair > Page 14624 7. Reinstall the window reveal molding. 1. Start from the loose area and hand-press the reveal molding into place over the edge of the window. 2. Run warm water over the reveal molding in order to speed the setup time of the urethane adhesive. 3. Tape should be applied in order to retain the reveal molding to the window. This will maintain a flush fit with the body. 4. The tape is to be removed after 6 hours. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair > Page 14625 Windshield Moulding / Trim: Service and Repair Windshield Side Reveal Molding Replacement Windshield Side Reveal Molding Replacement Removal Procedure 1. Pull back the front door sealing weatherstrip (1) to expose the windshield reveal molding screws. 2. Remove the screws from the windshield reveal molding. 3. Remove the windshield reveal molding from the windshield pillar. Installation Procedure 1. Install the windshield reveal molding to the windshield pillar. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the windshield reveal molding. Tighten the screws to the windshield reveal molding to 2 N.m (18 lb in). 3. Install the front door sealing weatherstrip (1) to the pinch-weld. 4. Close the door. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair > Page 14626 Windshield Moulding / Trim: Service and Repair Windshield Upper Reveal Molding Replacement Windshield Upper Reveal Molding Replacement Tools Required * Urethane Adhesive Kit GM P/N 12346392 or Equivalent * Isopropyl Alcohol or Equivalent * Cartridge-type Caulking Gun * Plastic Paddle Removal Procedure 1. Remove both right and left sides of the reveal molding. Caution: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. Important: The windshield reveal molding fills the cavities between the body and windshield. If the reveal molding is stretched or damaged it and cannot be reused it must be replaced. 2. Remove the upper windshield reveal molding. 1. Use a flat-bladed tool in order to carefully pry the end of the upper reveal molding out about 76 mm (3 in). 2. Grasp the corner of the windshield reveal molding by hand or use a suitable tool to slowly pull the reveal molding away from the windshield. 3. If the windshield reveal molding will not release, use a utility knife to aid in the releasing of the molding. Installation Procedure 1. Clean the top edge of the windshield surface with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint - free cloth. 2. The new reveal molding should be fitted to the windshield prior to installation. Caution: Refer to Window Retention Caution in Service Precautions. 3. Verify all primers and urethane adhesive are within expiration dates. Important: Use care when applying the prep (clear #1) to the windshield. This primer dries almost instantly, and may stain the viewing area of the windshield if not applied evenly. 4. Use a new dauber in order to apply glass prep (clear #1) to the channel area approximately 13 mm (1/2 in) to the upper edge of the windshield. 5. Wipe the glass primed area immediately with a clean lint-free cloth. 6. Shake the glass primer (black #2) for at least one minute. Using a new dauber in order to apply glass primer (black #2) to the top edge of the windshield. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair > Page 14627 7. Apply a small bead of urethane adhesive (2) between the windshield (1) and the pinchweld. 8. Install the upper reveal molding. 1. Start from the center and hand-press the reveal molding into place over the edge of the windshield. 2. Install both right and left sides of the reveal molding. 3. Run warm water over the reveal molding in order to speed the setup time of the urethane adhesive. Tape should be applied in order to retain the reveal molding to the windshield, this will maintain a flush fit with the body. The tape is to be removed after 6 hours. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair Front Fender Liner: Service and Repair Wheelhouse Panel Replacement Removal Procedure 1. Remove the push-in retainers from the wheelhouse panel. 2. Remove the top clips (2) retaining the harness to the top of the wheelhouse panel. 3. Install the retainers for Avalanche only. 4. Remove the wheelhouse panel from the wheelhouse. Installation Procedure 1. Install the wheelhouse panel to the wheelhouse. 2. Install the top clips (2) retaining the harness to the top of the wheelhouse panel. 3. Install the retainers for Avalanche only. 4. Install the push-in retainers to the wheelhouse panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Fender > Rear Fender > System Information > Service and Repair > Fender Replacement - Rear (Rear Dual Wheel) Rear Fender: Service and Repair Fender Replacement - Rear (Rear Dual Wheel) Fender Replacement - Rear (Rear Dual Wheel) Removal Procedure 1. Remove the upper molding rear retainer (1) from the fender. 2. Remove the upper molding from the fender. Use a flat-bladed tool in order to release the top molding retainers. 3. Remove the fuel filler neck from the vehicle, if necessary. 4. Remove the bolts from the front of the fender. 5. Remove the rear taillamp assembly from the vehicle. 6. Remove the bolts that retain the fender to the rear pillar. Remove the bolts through the taillamp opening. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Fender > Rear Fender > System Information > Service and Repair > Fender Replacement - Rear (Rear Dual Wheel) > Page 14637 7. Remove the lower bolts from the rear of the fender. 8. Disconnect the electrical connectors from the running lights, if equipped. 9. Remove the screws from the wheelwell. 10. Remove the bolts from the bottom of the fender. 11. With an assistant, pivot the fender from the bottom to approximately 90 degrees in order to remove the fender. Installation Procedure 1. With an assistant, install the fender to the pickup box at a 90 degree angle and lower gently. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the bottom of the fender. Tighten the bolts to 25 N.m (18 lb ft). 3. Install the screws to the wheelwell area. Tighten the screws to 2 N.m (18 lb in). 4. Connect the electrical connectors to the running lamps, if equipped. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Fender > Rear Fender > System Information > Service and Repair > Fender Replacement - Rear (Rear Dual Wheel) > Page 14638 5. Install the lower bolts to the rear of the fender. Tighten the bolts to 25 N.m (18 lb ft). 6. Install the bolts in order to retain the fender to the rear pillar. Tighten the bolts to 23 N.m (17 lb ft). 7. Install the rear taillamp assembly to the vehicle. 8. Install the bolts to the front of the fender. Tighten the bolts to 23 N.m (17 lb ft). 9. Install the fuel filler neck to the vehicle, if removed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Fender > Rear Fender > System Information > Service and Repair > Fender Replacement - Rear (Rear Dual Wheel) > Page 14639 10. Install the upper molding to the pickup box side. Align the locator pins (2) and press down in order to secure. 11. Install the upper molding rear retainer to the pickup box side. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Fender > Rear Fender > System Information > Service and Repair > Fender Replacement - Rear (Rear Dual Wheel) > Page 14640 Rear Fender: Service and Repair Fender Replacement - Rear (Step Side) Fender Replacement - Rear (Step Side) Removal Procedure 1. Remove the front filler bolts. 2. Remove the step pad. 3. Remove the lower fender brace rod bolts. 4. Remove the fender step bolts. 5. Remove the fender molding push-pins. 6. Remove the tail lamp assembly. 7. Remove the fender to rear pillar retaining bolts through the tail lamp opening. 8. Remove the rear retaining screws. 9. Remove the top fender molding push-pin retainer. 10. Remove the top fender molding. 11. Use the following procedure in order to remove the fender from the vehicle: 1. Lift the fender up 90 degrees. 2. Slide the fender outward. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Fender > Rear Fender > System Information > Service and Repair > Fender Replacement - Rear (Rear Dual Wheel) > Page 14641 Installation Procedure 1. Use the following procedure in order to install the fender to the vehicle: 1. Position the locating notch in the fender to the vehicle. 2. Rotate the fender up 90 degrees. 3. Slide the fender under the retainers. 4. Rotate the fender down 90 degrees into the body position. 2. Install the rear retaining screws. 3. Install the fender to the rear pillar retaining bolts through the tail lamp opening. 4. Install the tail lamp assembly. 5. Install the fender step bolts. 6. Install the step pad. 7. Install the front filler bolts. 8. Install the lower fender brace rods bolts. 9. Install the top fender molding. 10. Install the top molding rear push-pin retainer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Firewall > Passenger Compartment Cross Beam > Component Information > Description and Operation Passenger Compartment Cross Beam: Description and Operation Magnesium Instrument Panel Support Instrument Panel Support The Instrument Panel Support is a one-piece component comprised of a magnesium steering column support (Fig. 1.21), which holds the instrumentation and steering column; a die-formed tube attaches to the passenger side and supports the dashboard. This assembly functions as a structural cross-vehicle beam, air-bag support, and instrument panel carrier, which consolidates many different steel and plastic components. The magnesium instrument panel support is designed to deform and absorb energy generated by a severe impact. NOTE: Under no circumstance is the magnesium support to be repaired in any way. If any of the following conditions are present after a collision, the magnesium support must be replaced: - Steering column capsules have released or column has collapsed. - The steel knee bolster brackets are bent. - The parts which attach to the magnesium support do not fit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Customer Interest for Body / Frame Mount Bushing: > 06-08-61-003F > Apr > 11 > Body/Frame - Underbody Pop/Clunk When Turning Body / Frame Mount Bushing: Customer Interest Body/Frame - Underbody Pop/Clunk When Turning TECHNICAL Bulletin No.: 06-08-61-003F Date: April 12, 2011 Subject: Underbody Pop or Clunk Type Noise While Turning or Driving on Uneven Road Surfaces (Install Body Mount Insulator) Models: 2004-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2004-2012 Chevrolet Avalanche, Silverado (Classic), Silverado, Suburban, Tahoe 2004-2012 GMC Sierra (Classic), Sierra Denali (Classic), Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-61-003E (Section 08 - Body and Accessories). Condition Some customers may comment on a pop or clunk type noise while turning or driving on uneven road surfaces. This noise can be heard and/or felt at either the driver's or front passenger floor pan area. Cause Under certain conditions, normal movement between the frame and the #1, #2 or #3 body mounts may cause this noise to occur. Diagnosis 1. If the vehicle is equipped with aftermarket (non-GM Accessory) running boards or the running board is mounted using the body mount bolt, remove the running boards prior to test driving the vehicle. This will eliminate the running boards as the possible cause of the noise. 2. Install the J-39570 Chassis Ears to the frame rail at or near the body mounts. 3. Test drive the vehicle to identify which mount is suspect. Correction Install an insulator at the suspect mount(s). The insulator should be installed between the upper portion of the body mount and the frame bracket. The #1 mount is the mount located just under the A-pillar. The #2 mount is the mount located just under the B-pillar. The #3 mount is the mount located just under the C-pillar. Use the procedure listed below. 1. Raise the vehicle on the hoist. It is recommended to use a four-post lift or strap the vehicle frame to the hoist arms. 2. For the left side mounts only, remove the intermediate park brake cable. Perform the following steps: 1. Remove the nut from the park brake equalizer. 2. Remove the intermediate cable from the equalizer. 3. Depress the retaining tabs that secure the park brake cable to the frame. 4. Pull slightly on the cable from the mounting area in order to provide slack for body movement without binding the cable. 3. Remove all of the body mount bolts on the side being repaired. 4. Properly support the body at the body mount area. Caution When you remove the body mount, do NOT separate the frame from the body more than is necessary. Possible personal injury and damage to multiple parts may result. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Customer Interest for Body / Frame Mount Bushing: > 06-08-61-003F > Apr > 11 > Body/Frame - Underbody Pop/Clunk When Turning > Page 14655 5. Lower the chassis accordingly in order to remove the upper portion of the body mount. 6. Install the new insulator to the bottom of the top portion of the body mount. The picture shows the insulator (1) location after the body mount is reassembled. 7. Install the body mount to the frame bracket. 8. Perform the following procedure before installing the bolts. 1. Clean the bolt threads of all the original thread locking compound. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker, GM P/N 89021297 (In Canada, use P/N 10953488). 9. Install the body mount bolts. Tighten For 2003, 2004 and 2005 model year, tighten the bolts to 85 Nm (63 lb ft). Tighten For 2006-2012 model year, tighten the bolts to 100 Nm (74 lb ft). 10. Reinstall the intermediate park brake cable (left side only). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body / Frame Mount Bushing: > 06-08-61-003F > Apr > 11 > Body/Frame - Underbody Pop/Clunk When Turning Body / Frame Mount Bushing: All Technical Service Bulletins Body/Frame - Underbody Pop/Clunk When Turning TECHNICAL Bulletin No.: 06-08-61-003F Date: April 12, 2011 Subject: Underbody Pop or Clunk Type Noise While Turning or Driving on Uneven Road Surfaces (Install Body Mount Insulator) Models: 2004-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2004-2012 Chevrolet Avalanche, Silverado (Classic), Silverado, Suburban, Tahoe 2004-2012 GMC Sierra (Classic), Sierra Denali (Classic), Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-61-003E (Section 08 - Body and Accessories). Condition Some customers may comment on a pop or clunk type noise while turning or driving on uneven road surfaces. This noise can be heard and/or felt at either the driver's or front passenger floor pan area. Cause Under certain conditions, normal movement between the frame and the #1, #2 or #3 body mounts may cause this noise to occur. Diagnosis 1. If the vehicle is equipped with aftermarket (non-GM Accessory) running boards or the running board is mounted using the body mount bolt, remove the running boards prior to test driving the vehicle. This will eliminate the running boards as the possible cause of the noise. 2. Install the J-39570 Chassis Ears to the frame rail at or near the body mounts. 3. Test drive the vehicle to identify which mount is suspect. Correction Install an insulator at the suspect mount(s). The insulator should be installed between the upper portion of the body mount and the frame bracket. The #1 mount is the mount located just under the A-pillar. The #2 mount is the mount located just under the B-pillar. The #3 mount is the mount located just under the C-pillar. Use the procedure listed below. 1. Raise the vehicle on the hoist. It is recommended to use a four-post lift or strap the vehicle frame to the hoist arms. 2. For the left side mounts only, remove the intermediate park brake cable. Perform the following steps: 1. Remove the nut from the park brake equalizer. 2. Remove the intermediate cable from the equalizer. 3. Depress the retaining tabs that secure the park brake cable to the frame. 4. Pull slightly on the cable from the mounting area in order to provide slack for body movement without binding the cable. 3. Remove all of the body mount bolts on the side being repaired. 4. Properly support the body at the body mount area. Caution When you remove the body mount, do NOT separate the frame from the body more than is necessary. Possible personal injury and damage to multiple parts may result. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body / Frame Mount Bushing: > 06-08-61-003F > Apr > 11 > Body/Frame - Underbody Pop/Clunk When Turning > Page 14661 5. Lower the chassis accordingly in order to remove the upper portion of the body mount. 6. Install the new insulator to the bottom of the top portion of the body mount. The picture shows the insulator (1) location after the body mount is reassembled. 7. Install the body mount to the frame bracket. 8. Perform the following procedure before installing the bolts. 1. Clean the bolt threads of all the original thread locking compound. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker, GM P/N 89021297 (In Canada, use P/N 10953488). 9. Install the body mount bolts. Tighten For 2003, 2004 and 2005 model year, tighten the bolts to 85 Nm (63 lb ft). Tighten For 2006-2012 model year, tighten the bolts to 100 Nm (74 lb ft). 10. Reinstall the intermediate park brake cable (left side only). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Frame Cushion or Insulator Replacement (Regular Cab) Body / Frame Mount Bushing: Service and Repair Frame Cushion or Insulator Replacement (Regular Cab) Frame Cushion or Insulator Replacement (Regular Cab) Removal Procedure Important: Ensure that the vehicle is unloaded prior to body removal. 1. Remove the master cylinder. Perform the following steps: 1. Remove the nuts retaining the master cylinder to the brake booster. 2. Remove the master cylinder from the brake booster. 3. Secure the cylinder away from the booster. 2. Raise the vehicle on the hoist. Refer to Vehicle Lifting. 3. Remove the park brake equalizer intermediate cable. Perform the following steps: 1. Remove the nut from the park brake equalizer intermediate cable. 2. Remove the intermediate cable from the equalizer. 3. Depress the retaining tabs that secure the park brake cable to the frame. 4. Pull slightly on the cable from the mounting area in order to provide slack for body movement without binding the cable. 4. Remove the body mount bolts. 5. Properly support the body in the area that the mounts will be replaced. Caution: When you remove the body cushions, do NOT separate the frame from the body more than is necessary. Possible personal injury and damage to multiple parts may result if you do not follow the guides outlined below: * Intermediate steering shaft-Do not allow the shaft to extend more than 25 mm (1 in). * Fuel tank filler hose-Do not stretch the hose excessively. * Tail/Turn signal lamp wiring/rear lamps junction block-Leave slack in the wires. * Park brake cable-Leave slack in the cable. * Body ground straps-Leave slack in the wire. Lower the chassis accordingly in order to remove the cushions (1) as necessary. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Frame Cushion or Insulator Replacement (Regular Cab) > Page 14664 1. Install the cushions (1) as necessary and raise the chassis accordingly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the body mount bolts. Tighten the bolts to 85 N.m (63 lb ft). 3. Install the park brake equalizer intermediate cable. Perform the following steps: 1. Pull rearward on the park brake cable to the original position. 2. Secure the cable retaining tabs to the frame. 3. Install the intermediate cable end to the equalizer. 4. Install the nut to the threaded end of the intermediate cable. Tighten the nut to 4 N.m (31 lb in). 4. Lower the vehicle. 5. Install the master cylinder. Perform the following steps: 1. Mount the master cylinder to the brake booster. 2. Install the master cylinder mounting nuts. Tighten the nuts to 36 N.m (27 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Frame Cushion or Insulator Replacement (Regular Cab) > Page 14665 Body / Frame Mount Bushing: Service and Repair Frame Cushion or Insulator Replacement (Extended Cab) Frame Cushion or Insulator Replacement (Extended Cab) Removal Procedure Important: Ensure that the vehicle is unloaded prior to body removal. 1. Remove the master cylinder. Perform the following steps: 1. Remove the nuts retaining the master cylinder to the brake booster. 2. Remove the master cylinder from the brake booster. 3. Secure the cylinder away from the booster. 2. Raise the vehicle on the hoist. Refer to Vehicle Lifting. 3. Remove the park brake equalizer intermediate cable. Perform the following steps: 1. Remove the nut from the park brake equalizer intermediate cable. 2. Remove the intermediate cable from the equalizer. 3. Depress the retaining tabs that secure the park brake cable to the frame. 4. Pull slightly on the cable from the mounting area in order to provide slack for body movement without binding the cable. 4. Remove the body mount bolts. 5. Properly support the body in the area that the mounts will be replaced. Caution: When you remove the body cushions, do NOT separate the frame from the body more than is necessary. Possible personal injury and damage to multiple parts may result if you do not follow the guides outlined below: * Intermediate steering shaft-Do not allow the shaft to extend more than 25 mm (1 in). * Fuel tank filler hose-Do not stretch the hose excessively. * Tail/Turn signal lamp wiring/rear lamps junction block-Leave slack in the wires. * Park brake cable-Leave slack in the cable. * Body ground straps-Leave slack in the wire. Lower the chassis accordingly in order to remove the cushions (1) as necessary. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Frame Cushion or Insulator Replacement (Regular Cab) > Page 14666 1. Install the cushions (1) as necessary and raise the chassis accordingly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the body mount bolts. Tighten the bolts to 85 N.m (63 lb ft). 3. Install the park brake equalizer intermediate cable. Perform the following steps: 1. Pull rearward on the park brake cable to the original position. 2. Secure the cable retaining tabs to the frame. 3. Install the intermediate cable end to the equalizer. 4. Install the nut to the threaded end of the intermediate cable. Tighten the nut to 4 N.m (31 lb in). 4. Lower the vehicle. 5. Install the master cylinder. Perform the following steps: 1. Mount the master cylinder to the brake booster. 2. Install the master cylinder mounting nuts. Tighten the nuts to 36 N.m (27 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Body/Frame - Revised Crossmember/Body Bolt Service Cross-Member: Technical Service Bulletins Body/Frame - Revised Crossmember/Body Bolt Service Bulletin No.: 05-08-61-005 Date: April 29, 2005 SERVICE MANUAL UPDATE Subject: Revised Crossmember/Body Mount Bolt Installation Information Models: 1999-2005 Cadillac Full-Size Pickup and Utility Models 1999-2005 Chevrolet Full-Size Pickup and Utility Models 1999-2005 GMC Full-Size Pickup and Utility Models This bulletin is being issued to revise all repair procedures that include reinstalling the front engine crossmember-to-frame bolts or any body mount bolts in the Frame and Underbody sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Before reinstalling front engine crossmember-to-frame bolts or any body mount bolts, you must do the following: 1. Remove all traces of the original thread locking material. 2. Clean the threads of the bolt with denatured alcohol, or equivalent, and allow to dry. 3. Apply Thread locker, P/N 12345493, (Canadian P/N 10953488). Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember Replacement - Front Engine (4WD) Cross-Member: Service and Repair Crossmember Replacement - Front Engine (4WD) Crossmember Replacement - Front Engine (4WD) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the differential carrier shield. 3. Remove the bolts retaining the crossmember to the frame. 4. Remove the crossmember from the vehicle. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember Replacement - Front Engine (4WD) > Page 14673 1. Install the crossmember to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts retaining the crossmember to the frame. Tighten the crossmember retaining bolts to 120 N.m (88 lb ft). 3. Install the differential carrier shield. 4. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember Replacement - Front Engine (4WD) > Page 14674 Cross-Member: Service and Repair Transmission Support Replacement Transmission Support Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Remove the nut retaining the transmission mount to the transmission support. 4. Raise the rear of the transmission. 5. Remove the bolts and the nuts retaining the transmission support to the frame. (15 series) 6. Remove the bolts and the nuts retaining the transmission support to the frame. (25/35 series) 7. Remove the transmission support from the frame. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember Replacement - Front Engine (4WD) > Page 14675 1. Install the transmission support to the frame. (15 series) 2. Install the transmission support to the frame. (25/35 series) Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolts and the nuts in order to retain the transmission support to the frame. Tighten the nuts to 95 N.m (70 lb ft). 4. Lower the rear of the transmission. 5. Install the transmission mount to the transmission support. 6. Install the nuts in order to retain the transmission mount to the transmission support. Tighten the nuts to 40 N.m (30 lb ft). 7. Remove the transmission jack. 8. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Structural Brace > Component Information > Service and Repair Structural Brace: Service and Repair Frame Brace Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the bolts retaining the frame brace to the frame. 3. Remove the frame brace from the vehicle. Installation Procedure 1. Install the frame brace to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Structural Brace > Component Information > Service and Repair > Page 14679 2. Install the bolts retaining the frame brace to the frame. Tighten the frame brace retaining bolts to 50 N.m (37 lb ft). 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Adapter Kit > Component Information > Technical Service Bulletins > Customer Interest for Trailer Adapter Kit: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Adapter Kit: Customer Interest Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Adapter Kit > Component Information > Technical Service Bulletins > Customer Interest for Trailer Adapter Kit: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 14688 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Adapter Kit > Component Information > Technical Service Bulletins > Customer Interest for Trailer Adapter Kit: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 14689 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Adapter Kit > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Adapter Kit: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Adapter Kit: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Adapter Kit > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Adapter Kit: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 14695 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Adapter Kit > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Adapter Kit: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 14696 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair Trailer Hitch Replacement Removal Procedure 1. Disconnect the trailer wiring harness. 2. Remove the hitch platform bolts from the frame rails and the rear bumper. 3. Remove the hitch platform from the vehicle. Installation Procedure 1. Position the hitch platform to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the platform hitch bolts to the frame rails and the rear bumper. Tighten the bolts to 125 N.m (92 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 14700 3. Connect the trailer wiring harness. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair Grille: Service and Repair Grille Replacement (Chevrolet) Removal Procedure 1. Open the hood. 2. Remove the upper air baffle. 3. Remove the headlamp. 4. Release the side grille retainer (1) from the fender (2). Remove the grille from the vehicle. 5. Release the upper grille retainer (1) and the lower grille retainer (2) from the vehicle. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Page 14704 1. Press in the side grille retainers (1) into the fender (2). 2. Press the upper grille retainer (1) and lower grille retainer (2) to the vehicle. 3. Install the headlamp. 4. Install the upper air baffle. 5. Close the hood. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-50-004A > Jul > 06 > Interior - Front Seat Arm Rest Hinge Broken Arm Rest: Customer Interest Interior - Front Seat Arm Rest Hinge Broken Bulletin No.: 06-08-50-004A Date: July 28, 2006 TECHNICAL Subject: Front Seat Armrest Hinge Breaking (Replace Lid) Models: 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL with Front Split Seat (RPO AE7) Supercede: This bulletin is being revised to include RPO Code and interior trim color code information. Please discard Corporate Bulletin Number 06-08-50-004 (Section 08 - Body and Accessories). Condition Some customers may comment that the lid for the armrest is broken. Correction Replace the armrest lid using the procedure below. 1. Open the armrest lid. 2. Remove the armrest inner panel. Use a flat-bladed screwdriver and place it between the two panels and pull to separate. 3. Fold the seat backs to gain access to the hinge pin. Using a punch, push the hinge pin out. 4. Install the two springs into the new armrest lid. 5. Align the two springs and the lid to the armrest and install the pin. 6. Install the inner lid to the armrest and close the lid. 7. Place the seat back in the upright position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-50-004A > Jul > 06 > Interior - Front Seat Arm Rest Hinge Broken > Page 14714 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-50-004A > Jul > 06 > Interior - Front Seat Arm Rest Hinge Broken Arm Rest: All Technical Service Bulletins Interior - Front Seat Arm Rest Hinge Broken Bulletin No.: 06-08-50-004A Date: July 28, 2006 TECHNICAL Subject: Front Seat Armrest Hinge Breaking (Replace Lid) Models: 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2006 GMC Sierra, Yukon, Yukon XL with Front Split Seat (RPO AE7) Supercede: This bulletin is being revised to include RPO Code and interior trim color code information. Please discard Corporate Bulletin Number 06-08-50-004 (Section 08 - Body and Accessories). Condition Some customers may comment that the lid for the armrest is broken. Correction Replace the armrest lid using the procedure below. 1. Open the armrest lid. 2. Remove the armrest inner panel. Use a flat-bladed screwdriver and place it between the two panels and pull to separate. 3. Fold the seat backs to gain access to the hinge pin. Using a punch, push the hinge pin out. 4. Install the two springs into the new armrest lid. 5. Align the two springs and the lid to the armrest and install the pin. 6. Install the inner lid to the armrest and close the lid. 7. Place the seat back in the upright position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-50-004A > Jul > 06 > Interior - Front Seat Arm Rest Hinge Broken > Page 14720 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Other Service Bulletins for Arm Rest: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel Steering Shaft: All Technical Service Bulletins Steering - Underhood Clunk Heard/Felt in Steering Wheel TECHNICAL Bulletin No.: 00-02-35-003N Date: March 26 2008 Subject: Clunking Noise Under Hood and Can Be Felt in Steering Wheel and/or Steering Column (Replace Upper Intermediate Steering Shaft [I-Shaft] Assembly) Models: 2002-2006 Cadillac Escalade Models 1999-2007 Chevrolet Silverado Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Models (Classic) 2000-2006 GMC Yukon, Yukon XL Models 2003-2006 HUMMER H2 Attention: This Service Bulletin DOES NOT include Mid-Size Utilities such as Buick Rainier, Chevrolet TrailBlazer Models, GMC Envoy Models or Oldsmobile Bravada. Refer to Service Bulletin 02-02-35-006A or newer for Mid-Size Utilities. Supercede: This bulletin is being revised to add diagnostic information (refer to Diagnostic Tips) to check the lower steering column bearing as a potential source of the noise. Please discard Corporate Bulletin Number 00-02-35-003M (Section 02-Steering). Condition Some customers may comment on a clunk-type noise coming from under the hood that also can be felt in the steering wheel. These conditions may be more noticeable when turning at low speeds on rough road surfaces. Diagnostic Tips Use the information below to help diagnose the source of the noise. ^ The lower steering column bearing may create the same noise as the intermediate shaft. Before replacing the I-shaft, verify the noise isn't being caused by movement from the lower steering column bearing. Check the bearing for movement by pushing up and down on the I-shaft where it attaches to the steering column. ^ Frame Snap and/or Popping Type Noise - A frame snap or popping type noise can be duplicated on rough or smooth road surfaces with steering wheel input to the left or the right. This type of noise can be HEARD and is typically louder with the windows rolled down. For additional information refer to Corporate Bulletin Number 03-08-61-002F or newer - Snap/Popping Type Noise Coming from Front of Vehicle (Remove Front Crossmember Change Fastener Orientation). ^ Intermediate Shaft Clunk - Intermediate shaft clunk is heard and FELT in the steering wheel and/or steering column area typically while driving on rough road surfaces with steering wheel input. Correction Important: ^ I-shaft P/N 19153614 has been designed to replace previous designed dampened and non-dampened I-shafts. The physical difference in the yoke size will accommodate all vehicles listed in this bulletin. ^ Due to the design of the new I-shaft, it is not possible to lubricate/grease the I-shaft. Replace the steering column upper intermediate shaft with an improved design shaft that will eliminate the clunk noise using the procedure listed below. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Other Service Bulletins for Arm Rest: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 14726 1. Set the front wheels in the straight ahead position. Notice: On the 2002 and later model year vehicles the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil. 2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles. 3. For 2002 and later vehicles install the J 42640 in the steering column lower access hole. 4. From under the hood remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft. 5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft. 6. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the carpet away from the accelerator pedal position (APP) sensor. 2. Remove the two nuts retaining the accelerator pedal to the bulkhead. 3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Other Service Bulletins for Arm Rest: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 14727 7. From inside the vehicle remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection. 8. Remove the upper intermediate steering shaft assembly. 1. From inside the vehicle slide the shaft down and off the steering column. 2. From inside the vehicle slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle. 9. Replace the upper intermediate shaft. 10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft. 11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft. 12. Install the upper bolt and nut. Tighten Tighten the bolt to 47 N.m (35 lb ft). 13. Install the lower bolt and nut. Tighten Tighten the bolt to 50 N.m (37 lb ft). 14. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the accelerator pedals into position on the bulkhead. 2. Install the two retaining nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Reposition the carpet into place. Parts Information Warranty Information For vehicles repaired under warranty use, the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Other Service Bulletins for Arm Rest: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 14728 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Other Service Bulletins for Arm Rest: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 14734 1. Set the front wheels in the straight ahead position. Notice: On the 2002 and later model year vehicles the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil. 2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles. 3. For 2002 and later vehicles install the J 42640 in the steering column lower access hole. 4. From under the hood remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft. 5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft. 6. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the carpet away from the accelerator pedal position (APP) sensor. 2. Remove the two nuts retaining the accelerator pedal to the bulkhead. 3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Other Service Bulletins for Arm Rest: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 14735 7. From inside the vehicle remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection. 8. Remove the upper intermediate steering shaft assembly. 1. From inside the vehicle slide the shaft down and off the steering column. 2. From inside the vehicle slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle. 9. Replace the upper intermediate shaft. 10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft. 11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft. 12. Install the upper bolt and nut. Tighten Tighten the bolt to 47 N.m (35 lb ft). 13. Install the lower bolt and nut. Tighten Tighten the bolt to 50 N.m (37 lb ft). 14. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the accelerator pedals into position on the bulkhead. 2. Install the two retaining nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Reposition the carpet into place. Parts Information Warranty Information For vehicles repaired under warranty use, the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Other Service Bulletins for Arm Rest: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 14736 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Page 14737 Arm Rest: Service and Repair Armrest Replacement Removal Procedure 1. Remove the door trim panel. 2. Remove the armrest retaining screws. 3. Remove the armrest from the panel. Installation Procedure 1. Install the armrest from the panel. 2. Install the armrest retaining screws. 3. Install the door trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair > Ashtray Replacement (Console) Ash Tray: Service and Repair Ashtray Replacement (Console) Ashtray Replacement (Console) Ashtray in the luxury console is replaced as an assembly with the cupholder. Refer to Cupholder Replacement (Luxury) Cupholder Replacement (Non-Luxury) Cupholder Replacement (Rear) Cupholder Replacement (Pro). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair > Ashtray Replacement (Console) > Page 14742 Ash Tray: Service and Repair Ashtray Replacement (Non-Console) Ashtray Replacement (Non-Console) Removal Procedure 1. Open the ashtray and press the tab (1). 2. Drill out the head of the rivet (1). 3. Remove the ashtray assembly from the trim panel. Installation Procedure 1. Install the ashtray assembly to the trim panel. 2. Install new rivets (1) to attach the ashtray to the trim panel. 3. Close the ashtray so that the tab (1) goes through the opening. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats Carpet: Technical Service Bulletins Interior - Proper Use of Floor Mats INFORMATION Bulletin No.: 10-08-110-001 Date: March 30, 2010 Subject: Information on Proper Use of Floor Mats Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly may cause interference with the accelerator or brake pedal. Please review the following safety guidelines regarding proper driver's side floor mat usage with the customer. Warning If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or increased stopping distance which can cause a crash and injury. Make sure the floor mat does not interfere with the accelerator or brake pedal. - Do not flip the driver's floor mat over (in an effort to keep the floor mat clean) - Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel) - Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber mats over carpeted floor mats) - Only use floor mats that are designed specifically for your vehicle - When using replacement mats, make certain the mats do not interfere with the accelerator or brake pedal before driving the vehicle If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is installed correctly and according to the instructions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 14747 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 14748 Carpet: Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 14749 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 14750 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures Carpet: Procedures Eliminating Unwanted Odors in Vehicles Eliminating Unwanted Odors in Vehicles GM Vehicle Care Odor Eliminator, GM P/N 12378554, US ACDelco 88900909, Canadian P/N 88901678, may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. This non-toxic, biodegradable, odorless product has been shown to greatly reduce or remove the following types of odor: * Objectionable smells of mold and mildew resulting from vehicle water leaks * Customer created odors, such as smoke You may safely use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet, and sound deadening materials. You may also induce this product into HVAC modules and instrument panel ducts for the control of non-bacterial related odors. Important: This product leaves no residual scent and should not be used as an air freshener. This product may result in the permanent elimination of an odor and may be preferable to customers whose allergies make them sensitive to perfumes. This product may effectively remove odors when directly contacting the odor source. In cases such as water leaks, use this product with diagnostic procedures to first eliminate the primary cause of the odor. Then use further applications on the residual odor to permanently correct the vehicle condition. How to Use this Product * Spray GM Vehicle Care Odor Eliminator directly or as an additive with carpet shampoo in steam cleaners. * Do not use on any interior surface that plain water would deteriorate, because this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of GM Vehicle Care Odor Eliminator. * Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a persistent or recurring odor, you may call to obtain additional information and usage suggestions. Floor Carpet Drying Floor Carpet Drying If the carpet or the pad or insulator is wet, use the following criteria for drying or for replacing the components: * For a 1-piece carpet assembly bonded to a cotton or a fiber padding, replace the entire assembly. * For a 2-piece carpet assembly with a cotton or a fiber padding, replace the padding only. While the carpet is out of the vehicle, dry the carpet using the method described below. * For a 1-piece carpet assembly bonded to a foam padding or attached to a synthetic padding, dry the carpet using the method described below. * For a 2-piece carpet assembly with a synthetic padding, dry the assembly using the method described below. Drying Method 1. If you observe puddles of liquid on the carpet face, use a wet vacuum to remove the excess moisture. 2. Blot the face of the carpet with a towel in order to absorb as much moisture as possible. 3. Point a fan at the affected area and air dry the carpet. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures > Page 14753 Carpet: Removal and Replacement Carpet Replacement - Rear Panel Carpet Replacement - Rear Panel Removal Procedure 1. Remove the rear window lower molding. 2. Remove the trim panel. 3. Remove the carpet retainers. 4. Remove the carpet from the vehicle. Installation Procedure Caution: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material size as the original installation. Always return the carpet to the original location. 1. Install the carpet. 2. Install the carpet retainers. 3. Install the trim panel. 4. Install the rear window lower molding. Carpet Replacement - Front (W/O HP2) Carpet Replacement - Front (W/O HP2) Removal Procedure 1. Remove the hinge pillar trim panel. 2. Remove the door sill plates. 3. Remove the front seats. 4. Remove the floor storage console. 5. Remove the center seat, if equipped. 6. Remove the control lever and the boot, if equipped. 7. Remove the rear seat, if equipped. 8. Remove the jack assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures > Page 14754 9. Remove the quarter trim panel. 10. Remove the lower bolt from the instrument panel (I/P) support post. 11. Remove the carpet from the vehicle. Installation Procedure Caution: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material size as the original installation. Always return the carpet to the original location. 1. Install the carpet to the vehicle. 2. Install the lower bolt to the I/P support post. 3. Install the rear quarter trim panel. 4. Install the jack assembly. 5. Install the rear seat if removed. 6. Install the shift lever and the boot, if equipped. 7. Install the center seat, if equipped. 8. Install the floor storage console. 9. Install the front seats. 10. Install the door sill plates. 11. Install the hinge pillar trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lock Cylinder > Component Information > Technical Service Bulletins > Interior - Console Lock Cylinder and Key Replacement Console Lock Cylinder: Technical Service Bulletins Interior - Console Lock Cylinder and Key Replacement Bulletin No.: 01-08-49-017A Date: August 13, 2007 INFORMATION Subject: Center Front Floor Console Compartment Lock Cylinder and Key Replacement Models: 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1999-2006 Chevrolet Silverado 2000-2002 Chevrolet Suburban, Tahoe 2007 Chevrolet Silverado Classic 1999-2000 GMC Denali 1999-2006 GMC Sierra 2000-2002 GMC Yukon, Yukon XL 2001-2002 GMC Yukon Denali, Yukon Denali XL 2007 GMC Sierra Classic Supercede: This bulletin is being revised to add additional model years, revise the pricing information and provide contact information for a new lock cylinder supplier. Please discard Corporate Bulletin Number 01-08-49-017 (Section 08 - Body and Accessories). All pricing information listed in this bulletin is in U.S. dollars and is subject to change without notice. Currently there are different methods for obtaining replacement lock cylinders and keys used in the center front floor console compartment on the above vehicles. If a replacement lock cylinder and/or keys are required, follow the appropriate procedure listed for that vehicle. 1999-2007 Chevrolet Silverado (Classic) 2000-2002 Chevrolet Suburban, Tahoe 1999-2007 GMC Sierra (Classic) 2000-2002 GMC Yukon, Yukon XL The lock cylinder used in the center front floor console compartment on these vehicles is sonically welded to the inside of the console cover/lid and as a result cannot be serviced by itself. If a replacement lock cylinder is needed, it will be necessary to order a replacement console cover assembly from GMSPO. The new cover assembly comes complete with a new coded lock cylinder and two new coded keys. See Group 16.650 of the appropriate GMSPO Parts Catalog for part number information. Also on these vehicles, if the customer has lost or damaged their console keys and the lock cylinder is okay, replacement keys can be obtained directly from A-1 Manufacturing. To order replacement keys, dealers should call A-1 at 1-877-725-2121, extension 16, and supply them with the three-digit code from the lock cylinder. In addition, dealers may E-mail A-1 at [email protected] or [email protected]. If contacted by 12 noon Eastern Standard Time (EST, A-1 will cut 2 keys to the code supplied and ship UPS with the following charges (shipping included): 1 day delivery -$31.70 2 day delivery - $27.00 3 day delivery - $23.40 In addition, dealers can order a set of 174 master keys (2 keys cut to each of the 174 codes). Each 2-key set comes in a labeled poly zippered bag. In addition to the 348 master keys (174 master keys X 2), 50 blank keys will also be included in poly bags for dealers to cut from the masters using a profile key cutter. Master keys and blanks will be shipped via UPS Ground with the following charges (including shipping): One set of 174 master keys (348 keys) and 50 blanks in poly bags - $254.10 Additional 50 blank keys in poly bags - $42.75 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1999-2000 GMC Yukon Denali Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lock Cylinder > Component Information > Technical Service Bulletins > Interior - Console Lock Cylinder and Key Replacement > Page 14760 2001-2002 GMC Yukon Denali and Yukon Denali XL On these vehicles, if a replacement lock cylinder is needed, it can be ordered from GMSPO. The replacement lock cylinder comes already coded with two keys. See Group 16.650 of the appropriate GMSPO Parts Catalog for part number information. If only replacement keys are needed, they can be obtained directly from A-1 Security Mfg. Corporation. See the ordering information listed above. Additional Information Additional replacement lock cylinders (random codes) can also be ordered directly from A-1 in quantities of 10. Each comes complete with 2 keys on a ring and packaged in a poly bag. Listed below is the cost of 10 replacement lock cylinders and keys including shipping: 1 day delivery - $66.63 ' 2 day delivery - $49.28 3 day delivery - $44.97 UPS Ground - $37.29 Blank keys can also be ordered directly from A-1 in quantities of 10. The blanks come in a poly bag and can be used with a profile key cutter to duplicate an existing key. The cost of 10 blanks is $15.40, which includes UPS Ground shipping. Ordering When ordering from A-1, please provide your dealership name, location, and dealer code for identification and if applicable, the 3-digit code from the customer's lock cylinder or key. Additional Shipping Charges Add an additional charge of $10.00 to the above quoted prices when shipping to Alaska, Hawaii, Canada and Puerto Rico. Add an additional $20.00 to the above quoted prices when shipping to remote locations in Alaska, Hawaii and Canada. Payment Terms A credit card is preferred. An account can be set up upon request, payment net 30 days. References will be required. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling The SIR Identification Views shown below illustrate the approximate location of all SIR components available for the vehicle. This will assist in determining the appropriate SIR Disabling and Enabling for a given service procedure. Refer to See: Restraint Systems/Air Bag Systems/Locations/SIR Zone Identification Views There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: - Do not expose inflator modules to temperatures above 65°C (150°F). - Verify the correct replacement part number. Do not substitute a component from a different vehicle. - Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: - Inflatable restraint sensing and diagnostic module (SDM) - Any Inflatable restraint air bag module - Inflatable restraint steering wheel module coil - Any Inflatable restraint sensor - Inflatable restraint seat belt pretensioners - Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Important: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 14765 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Passenger Compartment Cross Beam > Component Information > Description and Operation Passenger Compartment Cross Beam: Description and Operation Magnesium Instrument Panel Support Instrument Panel Support The Instrument Panel Support is a one-piece component comprised of a magnesium steering column support (Fig. 1.21), which holds the instrumentation and steering column; a die-formed tube attaches to the passenger side and supports the dashboard. This assembly functions as a structural cross-vehicle beam, air-bag support, and instrument panel carrier, which consolidates many different steel and plastic components. The magnesium instrument panel support is designed to deform and absorb energy generated by a severe impact. NOTE: Under no circumstance is the magnesium support to be repaired in any way. If any of the following conditions are present after a collision, the magnesium support must be replaced: - Steering column capsules have released or column has collapsed. - The steel knee bolster brackets are bent. - The parts which attach to the magnesium support do not fit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Cupholder Replacement (Luxury) Drink Holders: Service and Repair Cupholder Replacement (Luxury) Cupholder Replacement (Luxury) Removal Procedure 1. Remove the upper trim bezel from the center console. 2. Remove the remote CD player if equipped. 3. Insert a flat bladed tool between the console and cupholder assembly. 4. Remove the cupholder assembly by prying the cupholder to release the clips (2). 5. Remove the wire connector for the cupholder. 6. Remove the cupholder from the console. Installation Procedure 1. Place the cupholder assembly over the console. 2. Connect the wire connector to the cupholder assembly. 3. Push on the corners of the cupholder assembly till all the retaining clips (2) are seated. 4. Install the remote CD player if equipped. 5. Install the upper trim bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Cupholder Replacement (Luxury) > Page 14773 Drink Holders: Service and Repair Cupholder Replacement (Non-Luxury) Cupholder Replacement (Non-Luxury) Removal Procedure 1. Grab the middle of the cup holder firmly and pull outwards to release the clips (1). 2. Remove the cup holder from the console. Installation Procedure 1. Install the cup holder by pushing inwards till the clips (1) click in place. 2. Ensure around the corners of the cup holder is seated properly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Cupholder Replacement (Luxury) > Page 14774 Drink Holders: Service and Repair Cupholder Replacement (Pro) Cupholder Replacement (Pro) Removal Procedure 1. Insert a flat bladed tool between the cupholder and console in order to pry the cupholder assembly out. 2. Lift the cupholder assembly slightly in order to disconnect the electrical connectors. 3. Remove the cupholder from the console. 4. Remove the switches from the cupholder assembly. 5. Remove the screws retaining the beverage-mate to the cupholder. 6. Remove the beverage-mate. Installation Procedure 1. Install the beverage-mate to the cupholder. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screws. Tighten the retaining screws to 1.6 N.m (14 lb in). 3. Install the switches to the cupholder assembly. 4. Connect the wire connectors to the switches. 5. Install the cupholder assembly to the console by pressing downwards until fully seated. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Cupholder Replacement (Luxury) > Page 14775 Drink Holders: Service and Repair Cupholder Replacement (Rear) Cupholder Replacement (Rear) Removal Procedure 1. Lower the cupholder. 2. Insert a flat bladed tool between the cupholder hinge and the end panel. 3. Pry off the cupholder from the console. Installation Procedure 1. Install one of the hinge in the opening in the panel. 2. Swing the cupholder assembly so that the other hinge can be installed in the other opening. 3. Inspect for correct operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Cupholder Replacement (Luxury) > Page 14776 Drink Holders: Service and Repair Cupholder Replacement - Front Seat Cupholder Replacement - Front Seat Removal Procedure 1. Remove the center seat. Caution: Eye protection must be worn when drilling rivets to reduce the chance of personal injury. 2. Remove the rivets (1) retaining the cupholder from the bottom of the center seat. 3. Remove the cupholder. Installation Procedure 1. Install the cupholder. 2. Install the rivets (1) retaining the cupholder to the bottom of the center seat. 3. Install the center seat. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair Glove Compartment: Service and Repair Compartment Replacement - Instrument Panel (I/P) Removal Procedure 1. Close the IP compartment door. 2. Drill out the 2 rivets (2). 3. Remove IP storage compartment door retaining screws (1) from the instrument panel. 4. Remove the IP compartment door. Installation Procedure 1. Install the IP compartment door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the IP compartment retaining screws (1) to the instrument panel. Tighten the screws to 1.9 N.m (17 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair Headliner Replacement Caution: Do not attempt to repair or alter the head impact energy-absorbing material glued to the headliner or to the garnish trims. If the material is damaged, replace the headliner and/or the garnish trim. Failure to do so could result in personal injury. Removal Procedure 1. Remove the I/P top trim panel. 2. Remove the hinge pillar trim. 3. Disconnect the headliner wire connectors from the junction block located next to the clutch or brake pedal. 4. Remove the wire harness retainers along the windshield pillar and I/P assembly. 5. Remove the rear quarter trim panels, if necessary. 6. Remove the overhead console, if equipped. 7. Remove the DVD player, if equipped. 8. Remove both front sunshades. 9. Remove the rear coat hook, if equipped. 10. Remove the interior dome lamp. 11. Remove the assist handles, if equipped. 12. Disengaging the front of the headliner from the roof. 13. If replacing the crew cab headliner, remove the rear window from the vehicle. Refer to Rear Window Replacement (Pickup) in Heated Glass Element. 14. Remove the headliner from the vehicle by grasping the headliner on the left and the right sides near the front of the cab. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 14783 1. With the aid of an assistant, install the headliner to the vehicle. 2. Install the rear window into the vehicle, if removed. 3. Install the assist handles, if equipped. 4. Install the interior dome lamp. 5. Install the rear coat hook, if equipped. 6. Install both front sunshades. 7. Install the DVD player, if equipped. 8. Install the overhead console, if equipped. 9. Install the rear quarter trim panels, if needed. Important: Ensure that all of the wire harness retainers in the I/P and the windshield pillar are all pressed into place in order to prevent rattling during driving. 10. Connect the headliner electrical connector to the junction block located next to the clutch or brake pedal. 11. Connect the electrical connectors to the drivers side accessory housing. 12. Install the hinge pillar trim. 13. Install the I/P top trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair > Assist Handle Replacement - Front Passenger Assist Handle: Service and Repair Assist Handle Replacement - Front Assist Handle Replacement - Front Removal Procedure 1. Lower the right side of the headliner. Refer to Headliner Replacement. 2. Turn the retainers in the directions as shown in the graphic and then remove the retainers. 3. Remove the assist handle from the headliner. Installation Procedure 1. Install the assist handle through the opening in the headliner. 2. While holding the assist handle to the head liner install the retainer in the direction as shown in the graphic. 3. Install the headliner. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair > Assist Handle Replacement - Front > Page 14788 Passenger Assist Handle: Service and Repair Assist Handle Replacement - Rear Assist Handle Replacement - Rear Removal Procedure 1. Remove center pillar trim panel. 2. Remove the assist handle retraining screws. 3. Remove the assist handle from the vehicle. Installation Procedure 1. Install the assist handle to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the assist handle screws. Tighten the screws to 6 N.m (53 lb in). 3. Install the center pillar trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair > Assist Handle Replacement - Front > Page 14789 Passenger Assist Handle: Service and Repair Instrument Panel (I/P) Assist Handle Replacement Instrument Panel (I/P) Assist Handle Replacement Removal Procedure 1. Remove both the passenger side air deflector louvers. 2. From the air deflector louver opening, press the release tabs on the instrument panel assist handle retainers on both sides. 3. Pull the assist handle from the instrument panel. Installation Procedure 1. Install the instrument panel assist handle by pushing until it locks into place. 2. Install both the passenger side air deflector louvers. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Door Sill Plate Replacement - Front Scuff Plate: Service and Repair Door Sill Plate Replacement - Front Door Sill Plate Replacement - Front Removal Procedure 1. Remove the sill plate. Firmly pull the sill plate up and out from the retainers. 2. Remove the sill plate from the vehicle. Start from the front of the door sill. Use a flat-bladed tool in order to pry the door sill plate. Installation Procedure 1. Install the sill plate. 2. Push the sill plate down until the sill plate locks into place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Door Sill Plate Replacement - Front > Page 14794 Scuff Plate: Service and Repair Door Sill Plate Replacement - Rear Door Sill Plate Replacement - Rear Removal Procedure 1. Use a flat-bladed tool in order to pry the door sill plate. 2. Remove the sill plate from the vehicle. Installation Procedure 1. Install the sill plate. 2. Push the sill plate down until the sill plate locks into place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > Customer Interest for Sun Visor: > 06-08-42-002A > Jan > 07 > Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. Sun Visor: Customer Interest Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. Bulletin No.: 06-08-42-002A Date: January 23, 2007 TECHNICAL Subject: Sunshade (Visor) Vanity Mirror Bulb Inoperative (Replace Vanity Mirror Bulb Only) Models: 2005-2007 Buick Allure (Canada Only), LaCrosse 2005-2007 Cadillac STS 2001-2005 Chevrolet Impala, Monte Carlo 2001-2006 Chevrolet Silverado Crew Cab, Suburban, Tahoe 2001-2006 GMC Sierra Crew Cab, Yukon, Yukon XL 2004-2005 Pontiac Grand Prix 2006-2007 HUMMER H3 Supercede: This bulletin is being updated to add the 2007 model year. Please discard Corporate Bulletin Number 06-08-42-002 (Section 08 - Body & Accessories). Condition Some customers may comment that a sunshade (visor) vanity mirror bulb is inoperative. Cause This condition may be caused by an inoperative bulb. Correction Do NOT replace the entire sunshade (visor) assembly. Replace the sunshade (visor) vanity mirror bulb with P/N 9442395 if repairing one of the affected models covered for an inoperative vanity mirror bulb. Refer to Vanity Mirror Lamp Replacement in SI. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > Customer Interest for Sun Visor: > 06-08-42-002A > Jan > 07 > Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. > Page 14803 The vanity mirror bulb can be accessed by removing the lens. Place a flat-bladed tool in the notches and gently pry out the lens. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Visor: > 06-08-42-002A > Jan > 07 > Interior Lighting Sun Visor Vanity Mirror Lamp Inop. Sun Visor: All Technical Service Bulletins Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. Bulletin No.: 06-08-42-002A Date: January 23, 2007 TECHNICAL Subject: Sunshade (Visor) Vanity Mirror Bulb Inoperative (Replace Vanity Mirror Bulb Only) Models: 2005-2007 Buick Allure (Canada Only), LaCrosse 2005-2007 Cadillac STS 2001-2005 Chevrolet Impala, Monte Carlo 2001-2006 Chevrolet Silverado Crew Cab, Suburban, Tahoe 2001-2006 GMC Sierra Crew Cab, Yukon, Yukon XL 2004-2005 Pontiac Grand Prix 2006-2007 HUMMER H3 Supercede: This bulletin is being updated to add the 2007 model year. Please discard Corporate Bulletin Number 06-08-42-002 (Section 08 - Body & Accessories). Condition Some customers may comment that a sunshade (visor) vanity mirror bulb is inoperative. Cause This condition may be caused by an inoperative bulb. Correction Do NOT replace the entire sunshade (visor) assembly. Replace the sunshade (visor) vanity mirror bulb with P/N 9442395 if repairing one of the affected models covered for an inoperative vanity mirror bulb. Refer to Vanity Mirror Lamp Replacement in SI. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Visor: > 06-08-42-002A > Jan > 07 > Interior Lighting Sun Visor Vanity Mirror Lamp Inop. > Page 14809 The vanity mirror bulb can be accessed by removing the lens. Place a flat-bladed tool in the notches and gently pry out the lens. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > Page 14810 Sun Visor: Service and Repair Sunshade Replacement Removal Procedure 1. Remove the screws. 2. Disconnect the electrical connector, if equipped. 3. Remove the sunshade. Installation Procedure 1. Connect the electrical connector, if equipped. 2. Install the sunshade. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the sunshade screws. Tighten the screw to 2 N.m (18 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - Center Pillar Trim Panel: Service and Repair Garnish Molding Replacement - Center Pillar Garnish Molding Replacement - Center Pillar Removal Procedure 1. Remove the door sill plates. 2. Remove the pillar moldings by holding the moldings firmly while pulling out. Installation Procedure 1. Install the pillar moldings by pushing until the molding locks into place. 2. Install the door sill trim plates. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - Center Pillar > Page 14815 Trim Panel: Service and Repair Garnish Molding Replacement - Windshield Pillar Garnish Molding Replacement - Windshield Pillar Removal Procedure 1. Pull the molding straight out in order to release the retainers. 2. Remove the windshield garnish molding. Installation Procedure 1. Ensure the bottom of the molding is seated in the slots on the I/P. 2. Align the molding retainers to the slots. 3. Press the moldings straight in till fully seated. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - Center Pillar > Page 14816 Trim Panel: Service and Repair Molding Replacement - Rear Window Lower Molding Replacement - Rear Window Lower Removal Procedure 1. Lightly pull the lower edge of the molding in order to release the clips. On extended cab fold the rear bench seat up. This will move the assembly forward so that the molding can be accessed. 2. Lift the molding up and away from the glass in order to release the upper retainers. Installation Procedure 1. Align the molding clips with the holes in the body panel along the back glass. 2. Snap the molding into place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - Center Pillar > Page 14817 Trim Panel: Service and Repair Trim Panel Replacement - Hinge Pillar Trim Panel Replacement - Hinge Pillar Removal Procedure 1. Remove the door-sill plate. 2. Remove the hinge pillar panel. Installation Procedure 1. Install the hinge pillar panel. 2. Install the door-sill plate. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - Center Pillar > Page 14818 Trim Panel: Service and Repair Garnish Molding Replacement - Center Pillar Garnish Molding Replacement - Center Pillar Removal Procedure 1. Remove the door sill plates. 2. Remove the pillar moldings by holding the moldings firmly while pulling out. Installation Procedure 1. Install the pillar moldings by pushing until the molding locks into place. 2. Install the door sill trim plates. Garnish Molding Replacement - Windshield Pillar Garnish Molding Replacement - Windshield Pillar Removal Procedure 1. Pull the molding straight out in order to release the retainers. 2. Remove the windshield garnish molding. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - Center Pillar > Page 14819 1. Ensure the bottom of the molding is seated in the slots on the I/P. 2. Align the molding retainers to the slots. 3. Press the moldings straight in till fully seated. Molding Replacement - Rear Window Lower Molding Replacement - Rear Window Lower Removal Procedure 1. Lightly pull the lower edge of the molding in order to release the clips. On extended cab fold the rear bench seat up. This will move the assembly forward so that the molding can be accessed. 2. Lift the molding up and away from the glass in order to release the upper retainers. Installation Procedure 1. Align the molding clips with the holes in the body panel along the back glass. 2. Snap the molding into place. Trim Panel Replacement - Hinge Pillar Trim Panel Replacement - Hinge Pillar Removal Procedure 1. Remove the door-sill plate. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - Center Pillar > Page 14820 2. Remove the hinge pillar panel. Installation Procedure 1. Install the hinge pillar panel. 2. Install the door-sill plate. Trim Panel Replacement - Rear Quarter (Crew Cab) Trim Panel Replacement - Rear Quarter (Crew Cab) Removal Procedure 1. Remove the coat hook, if required. 2. Remove the rear window lower molding. 3. Remove the quarter panel trim screws. 4. Remove the lower seat belt anchor bolt in order to guide the seat belt through the trim panel. 5. Remove the quarter panel. Installation Procedure 1. Install the seat belt through the trim panel. 2. Install the quarter panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the lower seat belt anchor bolt. Tighten the bolt to 53 N.m (39 lb ft). 4. Install the quarter panel trim screws. Tighten the quarter panel trim screws to 2 N.m (18 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - Center Pillar > Page 14821 5. Install the rear window lower molding. 6. Install the coat hook, if removed. Trim Panel Replacement - Rear Quarter (Extended Cab) Trim Panel Replacement - Rear Quarter (Extended Cab) Removal Procedure 1. Remove the rear seat, if necessary. 2. Remove the rear window molding. 3. Remove the armrest screw. 4. Remove the armrest. 5. Remove the sill trim plates. 6. Remove the quarter panel trim screws. 7. Pull the panel out, and remove the seat belt assembly. Refer to Seat Belt Retractor Replacement - Rear (Extended Cab) Seat Belt Retractor Replacement - Rear (Crew Cab) in Seat Belts. 8. Remove the quarter panel from the vehicle. Installation Procedure 1. Install the seat belt assembly. 2. Install the quarter panel to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - Center Pillar > Page 14822 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the quarter panel trim screws. Tighten the quarter panel trim screws to 2 N.m (18 lb in). 4. Install the sill trim plates. 5. Install the armrest. 6. Install the armrest screw. Tighten the armrest screw to 2 N.m (18 lb in). 7. Install the rear window molding. 8. Install the rear seat if necessary. Trim Panel Replacement - Rear Quarter (Regular Cab) Trim Panel Replacement - Rear Quarter (Regular Cab) Removal Procedure 1. Remove the coat hook. 2. Remove the jack and tool stowage. 3. Remove the rear window lower molding. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - Center Pillar > Page 14823 4. Remove the quarter panel trim screws. 5. Remove the rear screw from the sill trim plate. 6. Remove the quarter panel. Installation Procedure 1. Install the quarter panel. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the quarter panel trim screws. Tighten the quarter panel trim screws to 2 N.m (18 lb in). 3. Install the rear screw into the sill trim plate. 4. Install the rear window lower molding. 5. Install the jack and tool stowage. 6. Install the coat hook. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Tool Storage Compartment Bracket Replacement (PRO) Utility Storage Compartment: Service and Repair Tool Storage Compartment Bracket Replacement (PRO) Tool Storage Compartment Bracket Replacement (PRO) Removal Procedure 1. Remove the tool storage compartment. 2. Remove the rear seat hinge filler panel cover and plastic push pins, in order to gain access to seat riser retaining nuts. 3. Remove the nuts that retain the tool storage compartment brackets (1), (2) to the seat riser studs. 4. Remove the brackets from the vehicle. Installation Procedure 1. Install the brackets to the vehicle and hand tighten the nuts. 2. Install the tool storage compartment. Notice: Refer to Fastener Notice in Service Precautions. 3. Tighten the nuts that retain the tool storage compartment brackets (1), (2) to the seat riser studs. Tighten the nuts to 50 N.m (36 lb ft). 4. Install the rear seat hinge filler panel cover and plastic push pins. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Tool Storage Compartment Bracket Replacement (PRO) > Page 14828 Utility Storage Compartment: Service and Repair Tool Storage Compartment Cover Support Assembly Replacement Tool Storage Compartment Cover Support Assembly Replacement Removal Procedure 1. Open the lid of the tool storage box. Caution: Eye protection must be worn when drilling rivets to reduce the chance of personal injury. Important: The storage box lid has spring tension. Be sure to secure the lid when removing the support assembly, if the storage box is not inside the vehicle. 2. Remove the rivets (1) from the upper lid (2). 3. Remove the rivets (3) from the lower box (4). 4. Remove the support assembly from the tool storage box. Installation Procedure 1. Install the support assembly to the storage box. 2. Install the rivets (3) to the lower box (4). 3. Install the rivets (1) to the upper lid (2). 4. Close the lid on the tool storage box. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Tool Storage Compartment Bracket Replacement (PRO) > Page 14829 Utility Storage Compartment: Service and Repair Tool Storage Compartment Lock Replacement (PRO) Tool Storage Compartment Lock Replacement (PRO) Removal Procedure Caution: Eye protection must be worn when drilling rivets to reduce the chance of personal injury. 1. Raise the rear seat. 2. Remove the rivets retaining the lock assembly to the tool storage compartment. 3. Remove the lock assembly from the vehicle. Installation Procedure 1. Install the lock assembly to the vehicle. 2. Install the rivets retaining the lock assembly to the tool storage compartment. 3. Lower the rear seat. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Tool Storage Compartment Bracket Replacement (PRO) > Page 14830 Utility Storage Compartment: Service and Repair Tool Storage Compartment Replacement (PRO) Tool Storage Compartment Replacement (PRO) Removal Procedure 1. Raise the rear seat. 2. Remove the nuts that retain the tool storage compartment to the mounting brackets. 3. Remove the tool storage compartment from the vehicle. Installation Procedure 1. Install the tool storage compartment to the vehicle. 2. Install the nuts that retain the tool storage compartment to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the nuts that retain the tool storage compartment to the mounting brackets. Tighten the nuts to 10 N.m (88 lb in). 4. Lower the rear seat. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair Door Lock Cylinder: Service and Repair Lock Cylinder Replacement - Door Removal Procedure 1. Raise the window completely. 2. Remove the front door trim panel. 3. Remove the water deflector. 4. Remove the outside door handle. 5. Remove the clip that retains the lock cylinder lever to the lock cylinder. 6. Remove the lock cylinder retainer. Remove the lock cylinder from the outside door handle. Installation Procedure 1. Install the lock cylinder into the outside door handle. 2. Install the clip. 3. Install the outside door handle. 4. Install the front door water deflector. 5. Install the front door trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder Switch > Component Information > Diagrams Door Latch Assembly (Key Cylinder Switch) - Driver C3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Locations Door Module: Locations Driver Door Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Locations > Page 14842 Front Passenger Door Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions Door Module: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14845 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14846 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14847 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14848 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14849 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14850 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14851 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14852 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14853 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14854 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14855 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14856 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14857 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14858 Door Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14859 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14860 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14861 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14862 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14863 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14864 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14865 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14866 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14867 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14868 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14869 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14870 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14871 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14872 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14873 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14874 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14875 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14876 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14877 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14878 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14879 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14880 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14881 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14882 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14883 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14884 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14885 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14886 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14887 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14888 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14889 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14890 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14891 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14892 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14893 Door Module: Connector Views Driver Door Module (DDM) - C1 (With RPO Code YE9) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14894 Driver Door Module (DDM) - C2 (With RPO Code YE9) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14895 Driver Door Module (DDM) - C2 (With RPO Code YE9) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14896 Driver Door Module (DDM) - C3 (With RPO Code YE9) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14897 Driver Door Module (DDM) - C3 (With RPO Code YE9) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14898 Driver Door Module (DDM) - C4 (With RPO Code YE9) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14899 Driver Door Module (DDM) - C4 (With RPO Code YE9) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14900 Driver Door Module (DDM) - C5 (With RPO Code AN3) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14901 Driver Door Module (DDM) - C5 (With RPO Code AN3) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14902 Front Passenger Door Module (FPDM) - C1 (With RPO Code YE9) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14903 Front Passenger Door Module (FPDM) - C2 (With RPO Code YE9) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14904 Front Passenger Door Module (FPDM) - C2 (With RPO Code YE9) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14905 Front Passenger Door Module (FPDM) - C3 (With RPO Code YE9) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14906 Front Passenger Door Module (FPDM) - C3 (With RPO Code YE9) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14907 Front Passenger Door Module (FPDM) - C4 (With RPO Code YE9) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14908 Front Passenger Door Module (FPDM) - C4 (With RPO Code YE9) Part 2 Front Passenger Door Module (FPDM) - C5 (With RPO Code AN3) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14909 Front Passenger Door Module (FPDM) - C5 (With RPO Code AN3) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14910 Door Module: Electrical Diagrams Door Control Module Diagram 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14911 Door Control Module Diagram 2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14912 Door Control Module Diagram 2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14913 Door Control Module Diagram 3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14914 Door Control Module Diagram 3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Page 14915 Door Module: Service and Repair DOOR CONTROL MODULE PROGRAMMING AND SETUP Driver Door Module After replacing the driver door module (DDM), perform the programing procedure. Refer to Service Programming System (SPS). See: Testing and Inspection/Programming and Relearning Passenger Door Module After replacing the passenger door module (PDM), perform the following programing and setup procedures: ‹› Service Programming System (SPS). See: Testing and Inspection/Programming and Relearning ‹› Transmitter Programming. See: Testing and Inspection/Programming and Relearning ‹› Control Module Setup. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 14920 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 14921 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 14922 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-52-005 > Jun > 04 > Keyless Entry - Inoperative Keyless Entry Module: Customer Interest Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-52-005 > Jun > 04 > Keyless Entry - Inoperative > Page 14932 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-52-005 > Jun > 04 > Keyless Entry Inoperative Keyless Entry Module: All Technical Service Bulletins Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-52-005 > Jun > 04 > Keyless Entry Inoperative > Page 14938 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 06-08-50-009F > Dec > 10 > Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set Seat Occupant Sensor: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC B0092 Set Bulletin No.: 02-09-41-002A Date: March 24, 2004 TECHNICAL Subject: Air Bag Lamp On, Passenger Air Bag Indicator Always Reads OFF, DTC B0092 Set (Repair Passenger Presence System (PPS) Sensor Harness) Models: 2003-2004 Cadillac Escalade, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon XL with Sensor Indicator Inflatable Restraint Front Passenger/Child Presence Detector (RPO ALO) Supercede: This bulletin is being revised to add the 2004 model year. Please discard Corporate Bulletin Number 02-09-41-002 (Section 09 - Restraints). Condition Some customers may comment that the Air Bag Lamp is on and the Passenger Air Bag indicator always reads OFF. Upon investigation, the technician may find DTC B0092 set. Cause The cause of this condition may be a shorted Passenger Presence System (PPS) sensor wire. The PPS sensor harness is located under the front passenger seat. This harness may be pinched between the seat frame and the track/riser. Correction Locate the PPS sensor (1) and inspect the harness for proper routing. If the harness is pinched between the seat frame and the track/riser, use the procedure listed below to repair wire(s). 1. Move the front passenger seat to the full rearward and full tilt up position. 2. Loosen the seat frame to track/riser nut and remove the harness. 3. Tighten the seat frame to track/riser nut. 4. Repair any damaged wires. Refer to Wiring Repairs in the Wiring Systems sub-section of the Service Manual. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set > Page 14948 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > 02-09-41-002A > Mar > 04 > SRS - Air Bag Lamp ON/DTC B0092 Set > Page 14958 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Description and Operation Keyless Entry Receiver: Description and Operation REMOTE CONTROL DOOR LOCK RECEIVER MODULE SYSTEM The remote control door lock receiver module system may also arm and disarm the CTD system. When the remote control door lock receiver receives a door lock or an unlock signal from the key fob, the remote control door lock receiver sends a message to the BCM. The message orders the BCM to perform the appropriate door lock/unlock command. The BCM detects the message and performs one of the following functions: - Locks the doors and enters the armed initiated mode - Unlocks the doors and enters the ready-to-arm mode Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Description and Operation > Page 14962 Keyless Entry Receiver: Service and Repair REMOTE CONTROL DOOR LOCK RECEIVER REPLACEMENT The remote control door lock module is incorporated into the passenger side window switch module. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair TRANSMITTER BATTERY REPLACEMENT REMOVAL PROCEDURE Under normal use, the battery in the transmitter will last about 2 years. For battery replacement, use a Panasonic(R) 3 volt, type CR2032, or equivalent. 1. Open the transmitter case and perform the following steps: 1.1. Insert a dime between the 2 halves of the transmitter near the key ring hole. 1.2. Twist the dime. 2. Remove the battery. INSTALLATION PROCEDURE 1. Install the battery with the (+) positive side down. 2. Close the transmitter case and perform the following steps: 2.1. Align the top and bottom covers. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair > Page 14967 2.2. Press together the top and the bottom covers. 2.3. Inspect the operation of the transmitter. 3. Synchronize the transmitter. Refer to Transmitter Synchronization. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Door Lock Cylinder Switch > Component Information > Diagrams Door Latch Assembly (Key Cylinder Switch) - Driver C3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams Power Door Lock Actuator: Diagrams Door Latch Assembly (Lock Actuator) - Driver C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 14975 Door Latch Assembly (Lock Actuator) - Front Passenger C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 14976 Door Latch Assembly (Lock Actuator) - LR C1 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 14977 Door Latch Assembly (Lock Actuator) - RR C1 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Procedures Power Door Lock Actuator: Procedures Lock Actuator Replacement - Front Door LOCK ACTUATOR REPLACEMENT - FRONT DOOR REMOVAL PROCEDURE 1. Raise the window glass. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Disconnect the inside door lock rod from the handle retainer clip. 5. Disconnect the manual door lock rod from the door retainer clips. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Procedures > Page 14980 6. Remove the rubber plug in order to disengage the outside handle rod retainer. 7. Disconnect the cylinder lock rod. 8. Remove the bolts which retain the door lock actuator to the door. 9. Remove the door lock actuator and control rods as an assembly. 10. Disconnect the electrical connector from the door lock actuator, if equipped. 11. Remove the control rods as necessary. INSTALLATION PROCEDURE 1. Install the control rods to the assembly. 2. Connect the electrical connectors to the door lock actuator, if equipped 3. Install the door lock actuator to the door. 4. Connect the outside door handle control rod. 5. Connect the cylinder lock rod. NOTE: Refer to Fastener Notice in Service Precautions. 6. Install the bolts which retain the door lock actuator to the door. Tighten Tighten the screws to 9 N.m (80 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Procedures > Page 14981 7. Connect the manual door lock to the door retainer clips. 8. Connect the inside door handle control rod to the lock assembly. 9. Connect the inside door lock rod to the handle retainer clip. 10. Install the water deflector. 11. Install the door trim panel. 12. Inspect the operation of all the related components. Lock Actuator Replacement - Rear Door LOCK ACTUATOR REPLACEMENT - REAR DOOR REMOVAL PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Procedures > Page 14982 1. Raise the window. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Disconnect the inside door lock rod from the handle retainer clip. 5. Disconnect the manual door lock rod from the door retainer clips. 6. Remove the rubber plug in order to disengage the outside handle rod retainer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Procedures > Page 14983 7. Disconnect the cylinder lock rod (1). 8. Remove the bolts (2) which retain the door lock actuator to the door. 9. Remove the door lock actuator and control rods as an assembly. 10. Disconnect the electrical connector from the door lock actuator, if equipped. 11. Remove the control rods as necessary. INSTALLATION PROCEDURE 1. Install the control rods to the assembly. 2. Connect the electrical connectors to the door lock actuator, if equipped. 3. Install the door lock actuator to the door. 4. Connect the outside door handle control rod. 5. Connect the cylinder lock rod. NOTE: Refer to Fastener Notice in Service Precautions. 6. Install the bolts which retain the door lock actuator to the door. Tighten Tighten the screws to 9 N.m (80 lb in). 7. Connect the manual door lock to the door retainer clips. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Procedures > Page 14984 8. Connect the inside door handle control rod to the lock assembly. 9. Connect the inside door lock rod to the handle retainer clip. 10. Install the water deflector. 11. Install the door trim panel. 12. Inspect the operation of all the related components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Procedures > Page 14985 Power Door Lock Actuator: Removal and Replacement Lock Actuator Replacement - Front Door Lock Actuator Replacement - Front Door Removal Procedure 1. Raise the window glass. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Disconnect the inside door lock rod from the handle retainer clip. 5. Disconnect the manual door lock rod from the door retainer clips. 6. Remove the rubber plug in order to disengage the outside handle rod retainer. 7. Disconnect the cylinder lock rod. 8. Remove the bolts which retain the door lock actuator to the door. 9. Remove the door lock actuator and control rods as an assembly. 10. Disconnect the electrical connector from the door lock actuator, if equipped. 11. Remove the control rods as necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Procedures > Page 14986 Installation Procedure 1. Install the control rods to the assembly. 2. Connect the electrical connectors to the door lock actuator, if equipped 3. Install the door lock actuator to the door. 4. Connect the outside door handle control rod. 5. Connect the cylinder lock rod. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the bolts which retain the door lock actuator to the door. Tighten the screws to 9 N.m (80 lb in). 7. Connect the manual door lock to the door retainer clips. 8. Connect the inside door handle control rod to the lock assembly. 9. Connect the inside door lock rod to the handle retainer clip. 10. Install the water deflector. 11. Install the door trim panel. 12. Inspect the operation of all the related components. Lock Actuator Replacement - Rear Door Lock Actuator Replacement - Rear Door Removal Procedure 1. Raise the window. 2. Remove the door trim panel. 3. Remove the water deflector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Procedures > Page 14987 4. Disconnect the inside door lock rod from the handle retainer clip. 5. Disconnect the manual door lock rod from the door retainer clips. 6. Remove the rubber plug in order to disengage the outside handle rod retainer. 7. Disconnect the cylinder lock rod (1). 8. Remove the bolts (2) which retain the door lock actuator to the door. 9. Remove the door lock actuator and control rods as an assembly. 10. Disconnect the electrical connector from the door lock actuator, if equipped. 11. Remove the control rods as necessary. Installation Procedure 1. Install the control rods to the assembly. 2. Connect the electrical connectors to the door lock actuator, if equipped. 3. Install the door lock actuator to the door. 4. Connect the outside door handle control rod. 5. Connect the cylinder lock rod. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the bolts which retain the door lock actuator to the door. Tighten the screws to 9 N.m (80 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Procedures > Page 14988 7. Connect the manual door lock to the door retainer clips. 8. Connect the inside door handle control rod to the lock assembly. 9. Connect the inside door lock rod to the handle retainer clip. 10. Install the water deflector. 11. Install the door trim panel. 12. Inspect the operation of all the related components. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Door Lock Switch - Driver (Base Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 14992 Door Lock Switch - Front Passenger (Base Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Procedures Power Door Lock Switch: Procedures Switch Replacement - Door Lock and Side Window - Driver SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - DRIVER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 14995 6. Remove the door module from the switch panel bezel. INSTALLATION PROCEDURE 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten Tighten the screw to 2 N.m (18 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 14996 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Switch Replacement - Door Lock and Side Window - Passenger SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - PASSENGER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 14997 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. INSTALLATION PROCEDURE 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 14998 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 14999 Power Door Lock Switch: Removal and Replacement Switch Replacement - Door Lock and Side Window - Driver Switch Replacement - Door Lock and Side Window - Driver Removal Procedure 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 15000 Installation Procedure 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. See: Testing and Inspection/Programming and Relearning Switch Replacement - Door Lock and Side Window - Passenger Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 15001 Switch Replacement - Door Lock and Side Window - Passenger Removal Procedure 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 15002 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS). See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Technical Service Bulletins > Mirrors - Heated Mirrors, Defrosting Time Heated Element: Technical Service Bulletins Mirrors - Heated Mirrors, Defrosting Time INFORMATION Bulletin No.: 08-08-64-011A Date: February 25, 2010 Subject: Information on Heated Electrochromatic Outside Rearview Mirror Performance Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-64-011 (Section 08 - Body and Accessories). Defrosting Time/Performance Concern The electrochromatic (auto-dimming) outside rearview mirror used on the driver's side of many GM vehicles is slower to defrost than the passenger side outside rearview mirror. This is a normal condition. The glass on the driver's side electrochromatic mirror is twice as thick as the traditional glass on the passenger side mirror. The heating elements for the mirrors on both sides draw the same wattage, therefore the driver's side mirror will take approximately twice as long to defrost as the passenger mirror (approximately four minutes versus two minutes). Should a customer indicate that the driver's side heated mirror is not functioning correctly, verify it's function based upon this information prior to replacing the mirror. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Technical Service Bulletins > Customer Interest for Memory Positioning Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation Memory Positioning Module: Customer Interest Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Technical Service Bulletins > Customer Interest for Memory Positioning Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 15017 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Technical Service Bulletins > Customer Interest for Memory Positioning Module: > 04-08-50-003 > Feb > 04 > Interior - Seat Memory Feature Appears Inoperative Memory Positioning Module: Customer Interest Interior - Seat Memory Feature Appears Inoperative Bulletin No.: 04-08-50-003 Date: February 26, 2004 INFORMATION Subject: Enabling Memory Seat Feature via DIC If Feature Appears Inoperative Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon Denali, Yukon Denali XL 2003-2004 HUMMER H2 with Steering Wheel Controls (RPO UK3) (standard on H2) If the memory seat feature appears inoperative, check the Driver Information Center (DIC). Many of the memory seat modules that were returned through the Warranty Parts Center for a condition of inoperative have shown No Trouble Found. The Driver Information Center (DIC), programmed for Seat Entry and Exit, is set to the default "Off" mode at the assembly plant. DO NOT REPLACE THE MEMORY SEAT MODULE. Perform the following procedure. Important: The following procedure will need to be completed for each Remote/Key selection. Using the DIC menu, do the following steps: 1. Set the "Seat Recall" to either "At Key In" or "On Remote" based on the customer's preference. 2. Set the "Exit Seat" to "On". 3. Adjust the following items: Memory Seat: 3.1. Driver's Seat (including the seat back, recliner, lumbar, and side wings) 3.2. Throttle and Brake Pedals (not available on H2 or Silverado and Sierra Trucks) 3.3. Outside Mirrors 3.4. Radio Station Presets 3.5. Last Chosen Climate Control System Settings (not available on Silverado or Sierra Trucks) 3.6. Press and hold the "1" or "2" (for driver 1 or 2) button of the memory control for three seconds. A double chime will sound to let you know that the position has been stored. Easy Exit Seat: 3.1. Press and release the 1 or 2 button or press the unlock button on the desired remote keyless entry transmitter. The seat will move to the stored memory position. 3.2. Adjust the seat to the desired exit position. 3.3. Press and hold the exit button of the memory control (located on the door) for three seconds. A double chime will sound to let you know that the position has been stored for the identified driver (1 or 2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Technical Service Bulletins > Customer Interest for Memory Positioning Module: > 04-08-50-003 > Feb > 04 > Interior - Seat Memory Feature Appears Inoperative > Page 15022 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Memory Positioning Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation Memory Positioning Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Memory Positioning Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 15028 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Memory Positioning Module: > 04-08-50-003 > Feb > 04 > Interior - Seat Memory Feature Appears Inoperative Memory Positioning Module: All Technical Service Bulletins Interior - Seat Memory Feature Appears Inoperative Bulletin No.: 04-08-50-003 Date: February 26, 2004 INFORMATION Subject: Enabling Memory Seat Feature via DIC If Feature Appears Inoperative Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon Denali, Yukon Denali XL 2003-2004 HUMMER H2 with Steering Wheel Controls (RPO UK3) (standard on H2) If the memory seat feature appears inoperative, check the Driver Information Center (DIC). Many of the memory seat modules that were returned through the Warranty Parts Center for a condition of inoperative have shown No Trouble Found. The Driver Information Center (DIC), programmed for Seat Entry and Exit, is set to the default "Off" mode at the assembly plant. DO NOT REPLACE THE MEMORY SEAT MODULE. Perform the following procedure. Important: The following procedure will need to be completed for each Remote/Key selection. Using the DIC menu, do the following steps: 1. Set the "Seat Recall" to either "At Key In" or "On Remote" based on the customer's preference. 2. Set the "Exit Seat" to "On". 3. Adjust the following items: Memory Seat: 3.1. Driver's Seat (including the seat back, recliner, lumbar, and side wings) 3.2. Throttle and Brake Pedals (not available on H2 or Silverado and Sierra Trucks) 3.3. Outside Mirrors 3.4. Radio Station Presets 3.5. Last Chosen Climate Control System Settings (not available on Silverado or Sierra Trucks) 3.6. Press and hold the "1" or "2" (for driver 1 or 2) button of the memory control for three seconds. A double chime will sound to let you know that the position has been stored. Easy Exit Seat: 3.1. Press and release the 1 or 2 button or press the unlock button on the desired remote keyless entry transmitter. The seat will move to the stored memory position. 3.2. Adjust the seat to the desired exit position. 3.3. Press and hold the exit button of the memory control (located on the door) for three seconds. A double chime will sound to let you know that the position has been stored for the identified driver (1 or 2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Memory Positioning Module: > 04-08-50-003 > Feb > 04 > Interior - Seat Memory Feature Appears Inoperative > Page 15033 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Calibration Procedure Memory Positioning Module: Service and Repair Memory Seat Calibration Procedure MEMORY SEAT CALIBRATION PROCEDURE The memory seat module uses position sensor inputs to establish soft stop locations for the adjuster motors several millimeters ahead of the physical limits of the adjuster assembly. After replacing a memory seat module or adjuster components, it may be necessary to reset the adjuster motor soft stop locations. When the repair procedure has been completed, operate the seat adjuster switch in every direction until the seat adjuster reaches its mechanical hard stop by repeatedly pressing and releasing the switch as necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Calibration Procedure > Page 15036 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the seat cushion. 2. Disconnect the upper electrical harness connectors (3). 3. Remove the module (2) retaining screws (1). 4. Slide the module to the right to disengage the lower retainers. 5. Disconnect the lower electrical harness connectors (2). 6. Remove the module from the vehicle. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Calibration Procedure > Page 15037 1. Position the module into the vehicle. 2. Connect the lower electrical harness connectors (2). 3. Slide the module (2) to the left to engage the lower retainers. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the module retaining screws (3). Tighten Tighten the screws to 3 N.m (26 lb in). 5. Connect the upper electrical harness connectors (3). 6. Install the seat cushion. 7. If a new memory seat module was installed, calibrate the seat. Refer to Memory Seat Calibration Procedure. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations Driver Door Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 15041 Seat Memory Switch: Diagrams Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 15042 Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 15043 Memory/Heated Seat Switch - Driver (DDM C5) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 15044 Memory/Heated Seat Switch - Driver (DDM C5) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 15045 Seat Memory Switch: Service and Repair MEMORY SEAT SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connector. 3. Release the front seat memory switch assembly retaining clips in order to remove the switch. 4. Remove the front seat memory switch assembly. INSTALLATION PROCEDURE 1. Install the front seat memory switch assembly to the front trim panel by pressing into place until fully seated. 2. Connect the electrical connector to the front seat memory switch assembly. 3. Install the front trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: Customer Interest Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 15055 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: All Technical Service Bulletins Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 15061 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 15071 Paint: By Symptom Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 15072 Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 15073 TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 15074 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service Precautions > Technician Safety Information Paint: Technician Safety Information Basecoat/Clearcoat Paint Systems CAUTION: - Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. - Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers.If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clear coat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: - Lifting of primer coats caused by overly aggressive solvents in subsequent layers - Loss of adhesion between layers due to incompatibility of resin systems - Solvent popping or pin holing due to inappropriate solvent selection - Poor through-curing due to incompatible hardener resins or insufficient reactivity - Gloss reduction due to incompatible resins and/or solvents - Poor color accuracy due to pigment interactions with incompatible resins and/or solvents - Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service Precautions > Technician Safety Information > Page 15077 Paint: Vehicle Damage Warnings Basecoat/Clearcoat Paint Systems CAUTION: - Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. - Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers.If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clear coat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: - Lifting of primer coats caused by overly aggressive solvents in subsequent layers - Loss of adhesion between layers due to incompatibility of resin systems - Solvent popping or pin holing due to inappropriate solvent selection - Poor through-curing due to incompatible hardener resins or insufficient reactivity - Gloss reduction due to incompatible resins and/or solvents - Poor color accuracy due to pigment interactions with incompatible resins and/or solvents - Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) Paint: Application and ID Color Compatibility Guide (Paint Codes) COLOR COMPATIBILITY GUIDE (Paint Codes) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15080 WA111B/95 - WA303D/25 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15081 WA303D/25 - WA379E/86 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15082 WA379E/86 - WA382E/11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15083 WA382E/11 - WA408G/44 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15084 WA408G/44 - WA519F/12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15085 WA519F/12 - WA5322/33 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15086 WA5322/33 - WA534F/54 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15087 WA534F/54 - WA5456/43 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15088 WA5456/43 - WA7156/46 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15089 WA722J/25 - WA722J/25 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15090 WA722J/25 - WA800J/98 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15091 WA800J/98 - WA805K/62 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15092 WA805K/62 - WA811K/87 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15093 WA811K/87 - WA812K/88 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15094 WA812K/88 - WA812K/88 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15095 WA812K/88 - WA815K/91 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15096 WA815K/91 - WA817K/63 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15097 WA817K/63 - WA817K/63 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15098 WA817K/63 - WA822K/97 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15099 WA822K/97 - WA8554/40 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15100 WA8554/40 - WA8554/40 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15101 WA8555/41 - WA8555/41 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15102 WA8555/41 - WA8555/41 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15103 WA8555/41 - WA8555/41 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15104 WA8555/41 - WA8555/41 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15105 WA8555/41 - WA8624/50 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15106 WA8624/50 - WA8624/50 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15107 WA8624/50 - WA8624/50 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15108 WA8743/28 - WA885K/70 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15109 WA885K/70 - WA913L/56 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15110 WA913L/56 - WA9260/74 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15111 WA9260/74 - WA9260/74 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15112 WA9260/74 - WA926L/59 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15113 WA926L/59 - WA929L/15 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15114 WA929L/15 - WA931L/68 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15115 WA931L/68 - WA9417/88 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15116 WA9417/88 - WA9539/47 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15117 WA9539/47 - WA9566/13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15118 WA9566/13 - WA964L/29 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15119 WA964L/29 - WA9792/39 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15120 WA9800/77 - WA994L/67 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15121 WA994L/67 - WA994L/67 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15122 WA994L/67 - WA994L/67 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15123 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15124 Paint: Application and ID Paint Identification Precautions PAINT IDENTIFICATION Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important Always refer to the GM Approved Refinish Materials book GM PIN 4901 MD This book identities the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: 1. A cathodic immersion primer 2. A primer/surfacer 3. A basecoat 4. A clear top coat (clearcoat) Refer to the Service Parts ID Label to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This includes paint technology, paint codes, trim level, and any special order paint colors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15125 Paint: Application and ID Parts ID Label Location The vehicle service parts identification label is located inside the instrument panel I/P compartment. The label is used to help identify the vehicle original parts and options. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 15126 Paint: Application and ID Paint Identification Paint Identification Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important: Always refer to the GM Approved Refinish Materials book GM P/N 4901M-D. This book identifies the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: * A cathodic immersion primer * A primer/surfacer * A basecoat * A clear top coat (clearcoat) Refer to Label - Service Parts ID in order to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This includes paint technology, paint codes, trim level, and any special order paint colors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Page 15127 Paint: Service and Repair Basecoat/Clearcoat Paint Systems Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Caution: Refer to Eye Protection Caution in Service Precautions. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers. If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clearcoat in an open panel. Always apply clearcoat to the next break point, body side molding, feature line, or the next panel. Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: * Lifting of primer coats caused by overly aggressive solvents in subsequent layers * Loss of adhesion between layers due to incompatibility of resin systems * Solvent popping or pinholing due to inappropriate solvent selection * Poor through-curing due to incompatible hardener resins or insufficient reactivity * Gloss reduction due to incompatible resins and/or solvents * Poor color accuracy due to pigment interactions with incompatible resins and/or solvents * Film defects, such as craters, blisters, orange peel loss of gloss, due to the use of inferior quality raw materials in incompatible products Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Description and Operation Radiator Support: Description and Operation Radiator Support Description The radiator support assembly is made of aluminum alloy. You can repair minor damage with ER-4043 welding wire and 100 percent argon shielding gas. The upper tie-bar (1) and the vertical support (2) portion of the radiator support assembly are bolt-on components. The tie-bar and the vertical support (2) are available as part of the radiator support assembly, or can be ordered separately. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Description and Operation > Page 15131 Radiator Support: Service and Repair Tie Bar Replacement - Upper Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the upper radiator baffle. 3. Remove the headlamps. 4. Remove the upper condenser mounting bolts. 5. Remove the bolts from the front end diagonal brace. 6. Remove the front end diagonal brace. 7. Remove the fan shroud. 8. Remove the tie bar to radiator brace bolts (1). Access the bolts from the rear of the upper radiator support using an extension. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Description and Operation > Page 15132 9. Remove the radiator mounting bolts from the rear side of the tie bar. 10. Remove the tie bar bolts. 11. Remove the upper headlamp housing support screws. 12. Remove the tie bar. Installation Procedure 1. Position the tie bar onto the lower radiator support. 2. Install the tie bar bolts hand tight. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Description and Operation > Page 15133 Important: Ensure that the alignment is proper. 3. Tighten the tie bar bolts. Tighten the tie bar bolts to 9 N.m (80 lb in). 4. Install the upper headlamp housing support screws. Tighten the upper headlamp housing support screws to 9 N.m (80 lb in). 5. Install the radiator mounting bolts onto the rear side of the tie bar. Tighten the radiator mounting bolts to 25 N.m (18 lb ft). 6. Install the tie bar to the radiator brace bolts (1). Access the bolts from the rear of the tie bar using an extension. Tighten the radiator brace bolts to 9 N.m (80 lb in). 7. Install the upper fan shroud. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Description and Operation > Page 15134 8. Install the front end diagonal brace. 9. Install the front end diagonal brace bolts. Tighten the front end diagonal brace bolts to 25 N.m (18 lb ft). 10. Install the upper condenser mounting bolts. Tighten the upper condenser mounting bolts to 9 N.m (80 lb in). 11. Install the headlamps. 12. Install the upper radiator baffle. 13. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Locations Door Module: Locations Driver Door Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Page 15139 Front Passenger Door Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions Door Module: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15142 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15143 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15144 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15145 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15146 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15147 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15148 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15149 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15150 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15151 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15152 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15153 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15154 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15155 Door Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15156 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15157 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15158 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15159 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15160 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15161 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15162 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15163 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15164 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15165 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15166 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15167 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15168 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15169 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15170 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15171 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15172 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15173 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15174 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15175 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15176 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15177 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15178 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15179 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15180 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15181 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15182 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15183 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15184 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15185 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15186 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15187 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15188 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15189 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15190 Door Module: Connector Views Driver Door Module (DDM) - C1 (With RPO Code YE9) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15191 Driver Door Module (DDM) - C2 (With RPO Code YE9) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15192 Driver Door Module (DDM) - C2 (With RPO Code YE9) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15193 Driver Door Module (DDM) - C3 (With RPO Code YE9) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15194 Driver Door Module (DDM) - C3 (With RPO Code YE9) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15195 Driver Door Module (DDM) - C4 (With RPO Code YE9) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15196 Driver Door Module (DDM) - C4 (With RPO Code YE9) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15197 Driver Door Module (DDM) - C5 (With RPO Code AN3) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15198 Driver Door Module (DDM) - C5 (With RPO Code AN3) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15199 Front Passenger Door Module (FPDM) - C1 (With RPO Code YE9) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15200 Front Passenger Door Module (FPDM) - C2 (With RPO Code YE9) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15201 Front Passenger Door Module (FPDM) - C2 (With RPO Code YE9) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15202 Front Passenger Door Module (FPDM) - C3 (With RPO Code YE9) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15203 Front Passenger Door Module (FPDM) - C3 (With RPO Code YE9) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15204 Front Passenger Door Module (FPDM) - C4 (With RPO Code YE9) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15205 Front Passenger Door Module (FPDM) - C4 (With RPO Code YE9) Part 2 Front Passenger Door Module (FPDM) - C5 (With RPO Code AN3) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15206 Front Passenger Door Module (FPDM) - C5 (With RPO Code AN3) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15207 Door Module: Electrical Diagrams Door Control Module Diagram 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15208 Door Control Module Diagram 2 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15209 Door Control Module Diagram 2 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15210 Door Control Module Diagram 3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15211 Door Control Module Diagram 3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Page 15212 Door Module: Service and Repair DOOR CONTROL MODULE PROGRAMMING AND SETUP Driver Door Module After replacing the driver door module (DDM), perform the programing procedure. Refer to Service Programming System (SPS). See: Testing and Inspection/Programming and Relearning Passenger Door Module After replacing the passenger door module (PDM), perform the following programing and setup procedures: ‹› Service Programming System (SPS). See: Testing and Inspection/Programming and Relearning ‹› Transmitter Programming. See: Testing and Inspection/Programming and Relearning ‹› Control Module Setup. See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-52-005 > Jun > 04 > Keyless Entry Inoperative Keyless Entry Module: Customer Interest Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-52-005 > Jun > 04 > Keyless Entry Inoperative > Page 15221 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-52-005 > Jun > 04 > Keyless Entry - Inoperative Keyless Entry Module: All Technical Service Bulletins Keyless Entry - Inoperative Bulletin No.: 04-08-52-005 Date: June 15, 2004 TECHNICAL Subject: Remote Keyless Entry (RKE) System Inoperative (Reprogram Passenger Door Module (PDM)) Models: 2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2004 GMC Sierra, Yukon, Yukon XL Condition Some customers may comment on any of the following conditions: ^ The RKE key fob does not function. ^ The "Service Tire Pressure Monitoring System" message is displayed, if equipped. ^ The passenger door will not unlock from the passenger's or driver's door switches. ^ The passenger door window is inoperative. Correction Reprogram the PDM with the Tech 2(R). Currently the Tech 2(R) software is not available for the 2004 model year. Engineering is aware of this and are working to release a new service calibration. In the meantime, build the Tech 2(R) as a 2003 model year and perform the reprogram using the procedure listed below. 1. Turn the ignition switch to the ON position. 2. Connect the Tech 2(R) to the vehicle's diagnostic link connector (DLC), power it up and press enter. ^ Select: Diagnostics. ^ Select model year: 2003. ^ Select: Light truck. ^ Select: Body. ^ Select the proper Product line. ^ Select the proper HVAC Type. ^ Select the proper Radio System type. ^ Select: Passenger Door Module. ^ Select: Special Functions. ^ Select: Refresh. Important: You must remove the described fuse in the next step for the "Refresh" program to be performed. If you do not remove the fuse for five seconds, the Tech 2 will continue to display "Test in Progress" and the program will not complete. ^ Remove the PDM fuse for 5 seconds from the fuse center located behind the panel on the left end of the instrument panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-52-005 > Jun > 04 > Keyless Entry - Inoperative > Page 15227 ^ Reinstall the fuse and fuse panel cover. ^ Press the "Enter" button to perform the "Refresh" function. ^ "Test in Progress" will be displayed and the right front passenger door lock will cycle once. ^ The screen will display "Procedure Completed". ^ Press the "Exit" button as necessary to return to the main menu screen. 3. Using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Important: The calibrations required for performing SPS reprogram in the next step are based on the type of exterior rearview mirror the vehicle has. To determine the correct calibration, check the Service Parts Identification Label on the vehicle for the RPO code for exterior mirrors. 4. Follow normal Service Programming System (SPS) to reprogram the passenger door module with the current calibration available in TIS 2000. 5. After reprogramming is complete, using the switches in the right front passenger door, verify that the power window and power door lock located in that door function properly. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Module: > NHTSA04V225000 > May > 04 > Recall 04V225000: Child Seat Anchorage Non-Compliance Child Seat: All Technical Service Bulletins Recall 04V225000: Child Seat Anchorage Non-Compliance Make / Models : Model/Build Years: Chevrolet / Express 2003 Chevrolet / Silverado 2003-2004 GMC / Savana 2003 GMC / Sierra 2003-2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID Number : 04V225000 Recall Date : MAY 10, 2004 COMPONENT: Seat Belts: Front: Anchorage Potential Number Of Units Affected : 736 SUMMARY: certain extended and regular cab pickup trucks and cargo vans converted to compressed natural gas (CNG) fail to conform to the requirements of Federal Motor Vehicle Safety Standard NO. 225, "Child Restraint Anchorage Systems." These vehicles have one seating position, the center rear seat, equipped with child restraint lower anchorages. CONSEQUENCE: The standard requires child seat lower anchorages in two seating positions for vehicles with three rear seating positions. The standard cab and cargo van vehicles, which only have front seating positions, have an air bag off switch to disable the front passenger air bag and do not have child restraint lower anchorages in the passenger seat. The standard requires passenger seat child seat lower anchorages in vehicles with an air bag off switch. however, the standard does not require vehicles with only front seating positions to have lower anchorage provisions if the vehicle is not equipped with an air bag off switch. REMEDY: To bring the standard cab and cargo van vehicles into compliance, dealers will inject epoxy into the air bag off switch to prevent air bag activation, relocate the switch behind the instrument panel and then install a cover over the resulting opening. The sun visor label and owner's manual will also be changed. the correction for the extended cab vehicle will consist of changing the front passenger seat to a seat that has child restraint lower anchorages. The recall began on September 9, 2004. Owners should contact Chevrolet at 1-800-630-2438 OR GMC AT 1-866-996-9463. NOTES: GM Recall NO. 04038. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Technical Service Bulletins > Customer Interest for Memory Positioning Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation Memory Positioning Module: Customer Interest Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Technical Service Bulletins > Customer Interest for Memory Positioning Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 15246 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Technical Service Bulletins > Customer Interest for Memory Positioning Module: > 04-08-50-003 > Feb > 04 > Interior - Seat Memory Feature Appears Inoperative Memory Positioning Module: Customer Interest Interior - Seat Memory Feature Appears Inoperative Bulletin No.: 04-08-50-003 Date: February 26, 2004 INFORMATION Subject: Enabling Memory Seat Feature via DIC If Feature Appears Inoperative Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon Denali, Yukon Denali XL 2003-2004 HUMMER H2 with Steering Wheel Controls (RPO UK3) (standard on H2) If the memory seat feature appears inoperative, check the Driver Information Center (DIC). Many of the memory seat modules that were returned through the Warranty Parts Center for a condition of inoperative have shown No Trouble Found. The Driver Information Center (DIC), programmed for Seat Entry and Exit, is set to the default "Off" mode at the assembly plant. DO NOT REPLACE THE MEMORY SEAT MODULE. Perform the following procedure. Important: The following procedure will need to be completed for each Remote/Key selection. Using the DIC menu, do the following steps: 1. Set the "Seat Recall" to either "At Key In" or "On Remote" based on the customer's preference. 2. Set the "Exit Seat" to "On". 3. Adjust the following items: Memory Seat: 3.1. Driver's Seat (including the seat back, recliner, lumbar, and side wings) 3.2. Throttle and Brake Pedals (not available on H2 or Silverado and Sierra Trucks) 3.3. Outside Mirrors 3.4. Radio Station Presets 3.5. Last Chosen Climate Control System Settings (not available on Silverado or Sierra Trucks) 3.6. Press and hold the "1" or "2" (for driver 1 or 2) button of the memory control for three seconds. A double chime will sound to let you know that the position has been stored. Easy Exit Seat: 3.1. Press and release the 1 or 2 button or press the unlock button on the desired remote keyless entry transmitter. The seat will move to the stored memory position. 3.2. Adjust the seat to the desired exit position. 3.3. Press and hold the exit button of the memory control (located on the door) for three seconds. A double chime will sound to let you know that the position has been stored for the identified driver (1 or 2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Technical Service Bulletins > Customer Interest for Memory Positioning Module: > 04-08-50-003 > Feb > 04 > Interior - Seat Memory Feature Appears Inoperative > Page 15251 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Memory Positioning Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation Memory Positioning Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Memory Positioning Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 15257 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Memory Positioning Module: > 04-08-50-003 > Feb > 04 > Interior - Seat Memory Feature Appears Inoperative Memory Positioning Module: All Technical Service Bulletins Interior - Seat Memory Feature Appears Inoperative Bulletin No.: 04-08-50-003 Date: February 26, 2004 INFORMATION Subject: Enabling Memory Seat Feature via DIC If Feature Appears Inoperative Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon Denali, Yukon Denali XL 2003-2004 HUMMER H2 with Steering Wheel Controls (RPO UK3) (standard on H2) If the memory seat feature appears inoperative, check the Driver Information Center (DIC). Many of the memory seat modules that were returned through the Warranty Parts Center for a condition of inoperative have shown No Trouble Found. The Driver Information Center (DIC), programmed for Seat Entry and Exit, is set to the default "Off" mode at the assembly plant. DO NOT REPLACE THE MEMORY SEAT MODULE. Perform the following procedure. Important: The following procedure will need to be completed for each Remote/Key selection. Using the DIC menu, do the following steps: 1. Set the "Seat Recall" to either "At Key In" or "On Remote" based on the customer's preference. 2. Set the "Exit Seat" to "On". 3. Adjust the following items: Memory Seat: 3.1. Driver's Seat (including the seat back, recliner, lumbar, and side wings) 3.2. Throttle and Brake Pedals (not available on H2 or Silverado and Sierra Trucks) 3.3. Outside Mirrors 3.4. Radio Station Presets 3.5. Last Chosen Climate Control System Settings (not available on Silverado or Sierra Trucks) 3.6. Press and hold the "1" or "2" (for driver 1 or 2) button of the memory control for three seconds. A double chime will sound to let you know that the position has been stored. Easy Exit Seat: 3.1. Press and release the 1 or 2 button or press the unlock button on the desired remote keyless entry transmitter. The seat will move to the stored memory position. 3.2. Adjust the seat to the desired exit position. 3.3. Press and hold the exit button of the memory control (located on the door) for three seconds. A double chime will sound to let you know that the position has been stored for the identified driver (1 or 2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Memory Positioning Module: > 04-08-50-003 > Feb > 04 > Interior - Seat Memory Feature Appears Inoperative > Page 15262 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Calibration Procedure Memory Positioning Module: Service and Repair Memory Seat Calibration Procedure MEMORY SEAT CALIBRATION PROCEDURE The memory seat module uses position sensor inputs to establish soft stop locations for the adjuster motors several millimeters ahead of the physical limits of the adjuster assembly. After replacing a memory seat module or adjuster components, it may be necessary to reset the adjuster motor soft stop locations. When the repair procedure has been completed, operate the seat adjuster switch in every direction until the seat adjuster reaches its mechanical hard stop by repeatedly pressing and releasing the switch as necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Calibration Procedure > Page 15265 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the seat cushion. 2. Disconnect the upper electrical harness connectors (3). 3. Remove the module (2) retaining screws (1). 4. Slide the module to the right to disengage the lower retainers. 5. Disconnect the lower electrical harness connectors (2). 6. Remove the module from the vehicle. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Calibration Procedure > Page 15266 1. Position the module into the vehicle. 2. Connect the lower electrical harness connectors (2). 3. Slide the module (2) to the left to engage the lower retainers. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the module retaining screws (3). Tighten Tighten the screws to 3 N.m (26 lb in). 5. Connect the upper electrical harness connectors (3). 6. Install the seat cushion. 7. If a new memory seat module was installed, calibrate the seat. Refer to Memory Seat Calibration Procedure. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Control Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation Power Seat Control Module: Customer Interest Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Control Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 15275 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Control Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation Power Seat Control Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Control Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 15281 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 15282 Driver Seat (1 Of 2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 15283 Power Seat Control Module: Diagrams Memory Seat Module - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 15284 Memory Seat Module - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 15285 Memory Seat Module - C3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 15286 Memory Seat Module - C3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 15287 Memory Seat Module - C3 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 15288 Memory Seat Module - C4 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 15289 Memory Seat Module - C4 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 05-08-50-008 > Aug > 05 > Interior - Intermittent Seat Heater Operation Seat Heater Control Module: Customer Interest Interior - Intermittent Seat Heater Operation Bulletin No.: 05-08-50-008 Date: August 19, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 05-08-05-008 > Aug > 05 > Interior - Heated Seats Intermittently Inoperative Seat Heater Control Module: Customer Interest Interior - Heated Seats Intermittently Inoperative Bulletin No.: 05-08-05-008 Date: August 18, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 05-08-50-008 > Aug > 05 > Interior - Intermittent Seat Heater Operation Seat Heater Control Module: All Technical Service Bulletins Interior - Intermittent Seat Heater Operation Bulletin No.: 05-08-50-008 Date: August 19, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 05-08-05-008 > Aug > 05 > Interior - Heated Seats Intermittently Inoperative Seat Heater Control Module: All Technical Service Bulletins Interior - Heated Seats Intermittently Inoperative Bulletin No.: 05-08-05-008 Date: August 18, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat: > NHTSA04V225000 > May > 04 > Recall 04V225000: Child Seat Anchorage Non-Compliance Child Seat: All Technical Service Bulletins Recall 04V225000: Child Seat Anchorage Non-Compliance Make / Models : Model/Build Years: Chevrolet / Express 2003 Chevrolet / Silverado 2003-2004 GMC / Savana 2003 GMC / Sierra 2003-2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID Number : 04V225000 Recall Date : MAY 10, 2004 COMPONENT: Seat Belts: Front: Anchorage Potential Number Of Units Affected : 736 SUMMARY: certain extended and regular cab pickup trucks and cargo vans converted to compressed natural gas (CNG) fail to conform to the requirements of Federal Motor Vehicle Safety Standard NO. 225, "Child Restraint Anchorage Systems." These vehicles have one seating position, the center rear seat, equipped with child restraint lower anchorages. CONSEQUENCE: The standard requires child seat lower anchorages in two seating positions for vehicles with three rear seating positions. The standard cab and cargo van vehicles, which only have front seating positions, have an air bag off switch to disable the front passenger air bag and do not have child restraint lower anchorages in the passenger seat. The standard requires passenger seat child seat lower anchorages in vehicles with an air bag off switch. however, the standard does not require vehicles with only front seating positions to have lower anchorage provisions if the vehicle is not equipped with an air bag off switch. REMEDY: To bring the standard cab and cargo van vehicles into compliance, dealers will inject epoxy into the air bag off switch to prevent air bag activation, relocate the switch behind the instrument panel and then install a cover over the resulting opening. The sun visor label and owner's manual will also be changed. the correction for the extended cab vehicle will consist of changing the front passenger seat to a seat that has child restraint lower anchorages. The recall began on September 9, 2004. Owners should contact Chevrolet at 1-800-630-2438 OR GMC AT 1-866-996-9463. NOTES: GM Recall NO. 04038. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Recalls for Child Seat: > NHTSA04V225000 > May > 04 > Recall 04V225000: Child Seat Anchorage Non-Compliance Child Seat: Recalls Recall 04V225000: Child Seat Anchorage Non-Compliance Make / Models : Model/Build Years: Chevrolet / Express 2003 Chevrolet / Silverado 2003-2004 GMC / Savana 2003 GMC / Sierra 2003-2004 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID Number : 04V225000 Recall Date : MAY 10, 2004 COMPONENT: Seat Belts: Front: Anchorage Potential Number Of Units Affected : 736 SUMMARY: certain extended and regular cab pickup trucks and cargo vans converted to compressed natural gas (CNG) fail to conform to the requirements of Federal Motor Vehicle Safety Standard NO. 225, "Child Restraint Anchorage Systems." These vehicles have one seating position, the center rear seat, equipped with child restraint lower anchorages. CONSEQUENCE: The standard requires child seat lower anchorages in two seating positions for vehicles with three rear seating positions. The standard cab and cargo van vehicles, which only have front seating positions, have an air bag off switch to disable the front passenger air bag and do not have child restraint lower anchorages in the passenger seat. The standard requires passenger seat child seat lower anchorages in vehicles with an air bag off switch. however, the standard does not require vehicles with only front seating positions to have lower anchorage provisions if the vehicle is not equipped with an air bag off switch. REMEDY: To bring the standard cab and cargo van vehicles into compliance, dealers will inject epoxy into the air bag off switch to prevent air bag activation, relocate the switch behind the instrument panel and then install a cover over the resulting opening. The sun visor label and owner's manual will also be changed. the correction for the extended cab vehicle will consist of changing the front passenger seat to a seat that has child restraint lower anchorages. The recall began on September 9, 2004. Owners should contact Chevrolet at 1-800-630-2438 OR GMC AT 1-866-996-9463. NOTES: GM Recall NO. 04038. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Procedures Head Rest: Procedures Head Restraint Retainer Replacement - Front Seat HEAD RESTRAINT RETAINER REPLACEMENT - FRONT SEAT REMOVAL PROCEDURE 1. Slide up the seat back trim cover in order to gain access to the rear cardboard panel fasteners. Refer to Seat Back Cover and Pad Replacement Front. 2. Remove the panel fasteners. Pull back the panel in order to gain access to the bushings. 3. Remove the head restraint retainers from the seat back frame by squeezing the retaining tabs together at the base of the guide(s) and lifting up. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Procedures > Page 15329 1. Install the head restraint retainers by pressing into the seat back frame until the retaining tabs snap into place at the bottom of the frame opening. 2. Position the cardboard panel to the seat back frame and install the panel fasteners. 3. Install the seat back trim cover. Head Restraint Replacement HEAD RESTRAINT REPLACEMENT REMOVAL PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Procedures > Page 15330 1. Raise the head restraint (1) to the full up position. 2. Insert a paper clip or a similar tool in the hole at the side edges of the head restraint retainers. 3. Press in on the tool in order to release the retainer clips (2). 4. Lift the head restraint from the retainers. INSTALLATION PROCEDURE 1. Install the head restraint (1) into the retainers. 2. Push the head restraint to the full down position. 3. Pull up in order to ensure that the head restraint engages with the head restraint retainers (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Procedures > Page 15331 Head Rest: Removal and Replacement Head Restraint Replacement Head Restraint Replacement Removal Procedure 1. Raise the head restraint (1) to the full up position. 2. Insert a paper clip or a similar tool in the hole at the side edges of the head restraint retainers. 3. Press in on the tool in order to release the retainer clips (2). 4. Lift the head restraint from the retainers. Installation Procedure 1. Install the head restraint (1) into the retainers. 2. Push the head restraint to the full down position. 3. Pull up in order to ensure that the head restraint engages with the head restraint retainers (2). Head Restraint Retainer Replacement - Front Seat Head Restraint Retainer Replacement - Front Seat Removal Procedure 1. Slide up the seat back trim cover in order to gain access to the rear cardboard panel fasteners. Refer to Seat Back Cover and Pad Replacement Front. 2. Remove the panel fasteners. Pull back the panel in order to gain access to the bushings. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Procedures > Page 15332 3. Remove the head restraint retainers from the seat back frame by squeezing the retaining tabs together at the base of the guide(s) and lifting up. Installation Procedure 1. Install the head restraint retainers by pressing into the seat back frame until the retaining tabs snap into place at the bottom of the frame opening. 2. Position the cardboard panel to the seat back frame and install the panel fasteners. 3. Install the seat back trim cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Technical Service Bulletins > Customer Interest for Memory Positioning Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation Memory Positioning Module: Customer Interest Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Technical Service Bulletins > Customer Interest for Memory Positioning Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 15346 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Technical Service Bulletins > Customer Interest for Memory Positioning Module: > 04-08-50-003 > Feb > 04 > Interior - Seat Memory Feature Appears Inoperative Memory Positioning Module: Customer Interest Interior - Seat Memory Feature Appears Inoperative Bulletin No.: 04-08-50-003 Date: February 26, 2004 INFORMATION Subject: Enabling Memory Seat Feature via DIC If Feature Appears Inoperative Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon Denali, Yukon Denali XL 2003-2004 HUMMER H2 with Steering Wheel Controls (RPO UK3) (standard on H2) If the memory seat feature appears inoperative, check the Driver Information Center (DIC). Many of the memory seat modules that were returned through the Warranty Parts Center for a condition of inoperative have shown No Trouble Found. The Driver Information Center (DIC), programmed for Seat Entry and Exit, is set to the default "Off" mode at the assembly plant. DO NOT REPLACE THE MEMORY SEAT MODULE. Perform the following procedure. Important: The following procedure will need to be completed for each Remote/Key selection. Using the DIC menu, do the following steps: 1. Set the "Seat Recall" to either "At Key In" or "On Remote" based on the customer's preference. 2. Set the "Exit Seat" to "On". 3. Adjust the following items: Memory Seat: 3.1. Driver's Seat (including the seat back, recliner, lumbar, and side wings) 3.2. Throttle and Brake Pedals (not available on H2 or Silverado and Sierra Trucks) 3.3. Outside Mirrors 3.4. Radio Station Presets 3.5. Last Chosen Climate Control System Settings (not available on Silverado or Sierra Trucks) 3.6. Press and hold the "1" or "2" (for driver 1 or 2) button of the memory control for three seconds. A double chime will sound to let you know that the position has been stored. Easy Exit Seat: 3.1. Press and release the 1 or 2 button or press the unlock button on the desired remote keyless entry transmitter. The seat will move to the stored memory position. 3.2. Adjust the seat to the desired exit position. 3.3. Press and hold the exit button of the memory control (located on the door) for three seconds. A double chime will sound to let you know that the position has been stored for the identified driver (1 or 2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Technical Service Bulletins > Customer Interest for Memory Positioning Module: > 04-08-50-003 > Feb > 04 > Interior - Seat Memory Feature Appears Inoperative > Page 15351 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Memory Positioning Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation Memory Positioning Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Memory Positioning Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 15357 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Memory Positioning Module: > 04-08-50-003 > Feb > 04 > Interior - Seat Memory Feature Appears Inoperative Memory Positioning Module: All Technical Service Bulletins Interior - Seat Memory Feature Appears Inoperative Bulletin No.: 04-08-50-003 Date: February 26, 2004 INFORMATION Subject: Enabling Memory Seat Feature via DIC If Feature Appears Inoperative Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Yukon, Yukon Denali, Yukon Denali XL 2003-2004 HUMMER H2 with Steering Wheel Controls (RPO UK3) (standard on H2) If the memory seat feature appears inoperative, check the Driver Information Center (DIC). Many of the memory seat modules that were returned through the Warranty Parts Center for a condition of inoperative have shown No Trouble Found. The Driver Information Center (DIC), programmed for Seat Entry and Exit, is set to the default "Off" mode at the assembly plant. DO NOT REPLACE THE MEMORY SEAT MODULE. Perform the following procedure. Important: The following procedure will need to be completed for each Remote/Key selection. Using the DIC menu, do the following steps: 1. Set the "Seat Recall" to either "At Key In" or "On Remote" based on the customer's preference. 2. Set the "Exit Seat" to "On". 3. Adjust the following items: Memory Seat: 3.1. Driver's Seat (including the seat back, recliner, lumbar, and side wings) 3.2. Throttle and Brake Pedals (not available on H2 or Silverado and Sierra Trucks) 3.3. Outside Mirrors 3.4. Radio Station Presets 3.5. Last Chosen Climate Control System Settings (not available on Silverado or Sierra Trucks) 3.6. Press and hold the "1" or "2" (for driver 1 or 2) button of the memory control for three seconds. A double chime will sound to let you know that the position has been stored. Easy Exit Seat: 3.1. Press and release the 1 or 2 button or press the unlock button on the desired remote keyless entry transmitter. The seat will move to the stored memory position. 3.2. Adjust the seat to the desired exit position. 3.3. Press and hold the exit button of the memory control (located on the door) for three seconds. A double chime will sound to let you know that the position has been stored for the identified driver (1 or 2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Memory Positioning Module: > 04-08-50-003 > Feb > 04 > Interior - Seat Memory Feature Appears Inoperative > Page 15362 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Calibration Procedure Memory Positioning Module: Service and Repair Memory Seat Calibration Procedure MEMORY SEAT CALIBRATION PROCEDURE The memory seat module uses position sensor inputs to establish soft stop locations for the adjuster motors several millimeters ahead of the physical limits of the adjuster assembly. After replacing a memory seat module or adjuster components, it may be necessary to reset the adjuster motor soft stop locations. When the repair procedure has been completed, operate the seat adjuster switch in every direction until the seat adjuster reaches its mechanical hard stop by repeatedly pressing and releasing the switch as necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Calibration Procedure > Page 15365 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement MEMORY SEAT CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the seat cushion. 2. Disconnect the upper electrical harness connectors (3). 3. Remove the module (2) retaining screws (1). 4. Slide the module to the right to disengage the lower retainers. 5. Disconnect the lower electrical harness connectors (2). 6. Remove the module from the vehicle. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Calibration Procedure > Page 15366 1. Position the module into the vehicle. 2. Connect the lower electrical harness connectors (2). 3. Slide the module (2) to the left to engage the lower retainers. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the module retaining screws (3). Tighten Tighten the screws to 3 N.m (26 lb in). 5. Connect the upper electrical harness connectors (3). 6. Install the seat cushion. 7. If a new memory seat module was installed, calibrate the seat. Refer to Memory Seat Calibration Procedure. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations Driver Door Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 15370 Seat Memory Switch: Diagrams Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 15371 Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 15372 Memory/Heated Seat Switch - Driver (DDM C5) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 15373 Memory/Heated Seat Switch - Driver (DDM C5) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 15374 Seat Memory Switch: Service and Repair MEMORY SEAT SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connector. 3. Release the front seat memory switch assembly retaining clips in order to remove the switch. 4. Remove the front seat memory switch assembly. INSTALLATION PROCEDURE 1. Install the front seat memory switch assembly to the front trim panel by pressing into place until fully seated. 2. Connect the electrical connector to the front seat memory switch assembly. 3. Install the front trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Control Module: > 04-08-50-016C > Aug > 05 > Interior Erratic Memory Seat Operation Power Seat Control Module: Customer Interest Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Control Module: > 04-08-50-016C > Aug > 05 > Interior Erratic Memory Seat Operation > Page 15383 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Control Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation Power Seat Control Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Control Module: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 15389 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 15390 Driver Seat (1 Of 2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 15391 Power Seat Control Module: Diagrams Memory Seat Module - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 15392 Memory Seat Module - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 15393 Memory Seat Module - C3 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 15394 Memory Seat Module - C3 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 15395 Memory Seat Module - C3 Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 15396 Memory Seat Module - C4 Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Technical Service Bulletins > Page 15397 Memory Seat Module - C4 Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations Power Seat Motor: Locations Passenger Presence Components - Under Front Passenger Seat Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 15401 Passenger Presence Components - Side of Front Passenger Seat Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 15402 Driver Seat (1 Of 2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 15403 Driver Seat (2 Of 2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 15404 Front Passenger Seat (1 Of 2) (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 15405 Front Passenger Seat (2 Of 2) (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Seat Recliner Motor Power Seat Motor: Diagrams Seat Recliner Motor Seat Recliner Motor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Seat Recliner Motor > Page 15408 Seat Recliner Motor - Front Passenger (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Seat Recliner Motor > Page 15409 Seat Bolster Motor - Front Passenger (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Seat Recliner Motor > Page 15410 Seat Lumbar Motor - Front Passenger (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Seat Recliner Motor > Page 15411 Power Seat Motor: Diagrams Seat Front Vertical Motor Seat Front Vertical Motor - Driver Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Seat Recliner Motor > Page 15412 Seat Front Vertical Motor - Front Passenger Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Seat Recliner Motor > Page 15413 Power Seat Motor: Diagrams Seat Rear Vertical Motor Seat Rear Vertical Motor - Driver Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Seat Recliner Motor > Page 15414 Seat Rear Vertical Motor - Front Passenger Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Page 15415 Power Seat Motor: Service and Repair SEAT ADJUSTER MOTOR REPLACEMENT - FRONT The seat adjuster motors can not be replaced individually. Therefore if any motor has failed, the seat adjuster needs to be replaced as an assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 15420 Seat Lumbar Motor/Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 15421 Seat Front Vertical Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 15422 Seat Horizontal Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 15423 Power Seat Motor Position Sensor: Diagrams Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 15424 Seat Lumbar Motor/Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 15425 Seat Front Vertical Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 15426 Seat Horizontal Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 15427 Seat Rear Vertical Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 15428 Seat Recliner Motor Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing Power Seat Switch: Customer Interest Interior - Power Seat Switch Knobs Loose/Missing Bulletin No.: 05-08-50-017 Date: December 14, 2005 TECHNICAL Subject: Power Front Seat (RPO AN3) Switch Knobs Loose or Missing (Replace Switch Knobs) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2006 GMC Sierra, Yukon, Yukon XL with Individual Front Seat Non-Bucket (RPO AN3) and Driver Front Seat Power Adjuster (AG1) and/or Passenger Front Seat Power Adjuster (AG2) Condition Some customers may comment that the power front seat adjuster switch knobs are loose and fall off or are missing. Correction Replace the front seat adjuster switch knob. These knobs were formerly available only as part of the power seat adjuster switch. DO NOT replace the switch if the knob only needs to be replaced. Parts Information Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing > Page 15437 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing Power Seat Switch: All Technical Service Bulletins Interior - Power Seat Switch Knobs Loose/Missing Bulletin No.: 05-08-50-017 Date: December 14, 2005 TECHNICAL Subject: Power Front Seat (RPO AN3) Switch Knobs Loose or Missing (Replace Switch Knobs) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2006 GMC Sierra, Yukon, Yukon XL with Individual Front Seat Non-Bucket (RPO AN3) and Driver Front Seat Power Adjuster (AG1) and/or Passenger Front Seat Power Adjuster (AG2) Condition Some customers may comment that the power front seat adjuster switch knobs are loose and fall off or are missing. Correction Replace the front seat adjuster switch knob. These knobs were formerly available only as part of the power seat adjuster switch. DO NOT replace the switch if the knob only needs to be replaced. Parts Information Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing > Page 15443 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 15444 Power Seat Switch: Locations Driver Seat (1 Of 2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 15445 Front Passenger Seat (1 Of 2) (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 15446 Power Seat Switch: Diagrams Seat Adjuster Switch - Driver (With RPO Code AN3) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 15447 Seat Adjuster Switch - Driver (With RPO Code AN3) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 15448 Seat Adjuster Switch - Driver (AG1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 15449 Seat Adjuster Switch- Front Passenger (With RPO Code AN3) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 15450 Seat Adjuster Switch- Front Passenger (With RPO Code AN3) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 15451 Seat Bolster/Lumbar Switch - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 15452 Seat Bolster/Lumbar Switch - Front Passenger (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Procedures Power Seat Switch: Procedures Lumbar Switch Replacement LUMBAR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the power seat switch bezel containing the lumbar switch (1) from the seat. 2. Remove the lumbar switch screws from the power seat switch bezel. 3. Remove the lumbar switch. INSTALLATION PROCEDURE 1. Install the lumbar switch to the power seat switch bezel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the lumbar switch screws. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the power seat switch bezel (1) to the seat. Seat Switch Bezel Replacement SEAT SWITCH BEZEL REPLACEMENT REMOVAL PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 15455 1. Remove the screws retaining the power seat switch bezel. 2. Disconnect the electrical connectors. 3. Remove the lumbar support switch. 4. Remove the power seat adjuster switch assembly. INSTALLATION PROCEDURE 1. Install the power seat adjuster switch assembly to the seat switch bezel. 2. Install the lumbar support switch to the seat switch bezel. 3. Connect the electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws retaining the power seat switch bezel. Tighten Tighten the screws to 2 N.m (18 lb in). Seat Switch Replacement - Power SEAT SWITCH REPLACEMENT - POWER REMOVAL PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 15456 1. Remove the power seat switch bezel from the seat. 2. Remove the power seat switch to bezel screws. 3. Remove the power seat switch. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the power seat switch to bezel screws. Tighten Tighten the screws to 2 N.m (18 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 15457 2. Install the power seat switch bezel to the seat. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 15458 Power Seat Switch: Removal and Replacement Seat Switch Replacement - Power Removal Procedure 1. Remove the power seat switch bezel from the seat. 2. Remove the power seat switch to bezel screws. 3. Remove the power seat switch. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the power seat switch to bezel screws. Tighten the screws to 2 N.m (18 lb in). 2. Install the power seat switch bezel to the seat. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Service and Repair > Seat Back Frame Replacement - Front Seat Back Frame: Service and Repair Seat Back Frame Replacement - Front SEAT BACK FRAME REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the head restraint and guides. 3. Remove the seat trim panel. 4. Disconnect the lumbar cable (6) underneath the seat cushion (disconnect the lumbar wire harness if equipped with power lumbar). 5. Remove the seat back trim cover and pad. 6. Remove the lumbar assembly (or power lumbar/bolster assembly if equipped). 7. Remove the seat belt retractor. 8. Remove the inboard pivot bolt (1). 9. Remove the recliner arm attachment bolts (2). 10. Remove the frame from the vehicle. 11. Transfer all necessary components to the new seat back frame. INSTALLATION PROCEDURE 1. Position the seat back frame on the seat. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 15464 2. Install the recliner arm attachment bolts (2). Tighten Tighten the bolts to 53 N.m (39 lb ft). 3. Install the inboard pivot bolt (1). Tighten Tighten the bolt to 35 N.m (26 lb ft). 4. Install the seat belt retractor. 5. Install the lumbar assembly (or power lumbar/bolster assembly if equipped). 6. Install the seat back trim cover and pad. 7. Connect the lumbar cable (6) underneath the seat cushion (disconnect the wire harness if equipped with power lumbar). 8. Install the seat trim panel. 9. Install the head restraint and guides. 10. Install the seat into the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 15465 Seat Back Frame: Service and Repair Seat Back Frame Replacement - Rear SEAT BACK FRAME REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the armrest, if equipped. 3. Partially remove the seat-back cover in order to gain access to the retaining bolts. 4. Remove the bolts from the seat-back frame. 5. Remove the seat-back frame (4) from the seat back cushion frame. INSTALLATION PROCEDURE 1. Install the seat-back frame (4) to the seat cushion frame. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolts which retain the seat-back frame to the seat cushion frame. Tighten Tighten the bolts to 35 N.m (26 lb ft). 3. Install the seat-back cover. 4. Install the armrest to the seat back. 5. Install the seat to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Recalls: > 06102B > Oct > 07 > Recall - Aftermarket Leather Seat Cover Kit Technical Service Bulletin # 06102B Date: 071019 Recall - Aftermarket Leather Seat Cover Kit Subject: Product Safety - Aftermarket Leather Seat Cover Kits # 06102B - (10/19/2007) 2005-2006 Buick LaCrosse, Rendezvous 2004 Chevrolet Silverado 2005 Chevrolet Tahoe 2005-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2006 Chevrolet HHR, Malibu 2005 GMC Sierra 2005-2006 GMC Envoy 2006 GMC Envoy XL 2006 HUMMER H3 2005 Pontiac Montana 2006 Pontiac G6 The telephone number for contacting General Motors has been changed. To assist customers with initiating the vehicle repurchase process, dealers should contact the GM Reacquired Vehicle Disclosure Center (RVDC). With dealer assistance, the RVDC will work with the customer to reach an agreement on the purchase and physical transfer of the vehicle. Condition General Motors has decided that a defect that relates to motor vehicle safety exists in aftermarket front passenger leather cover kits that were installed at its request on certain vehicles with the Passenger Sensing System. Recently, testing on these seat covers indicated that they can cause the Passenger Sensing system to malfunction. If the Passenger Sensing System malfunctions, the front airbag on the passenger side may be disabled when it should be enabled, or enabled when it should be disabled. In either case, in the event of a crash that requires airbag deployment, a front passenger's level of injury may be increased. The airbag status indicator displays the status of the airbag. Whenever the front passenger seat is occupied, the driver should always check the airbag indicator to see if the airbag is on or off as explained in the owner manual. If it is not correct for the situation, the passenger should be moved to a different seat. Correction Because a replacement leather seat cover that is compatible with the Passenger Sensing System is not available, General Motors will repurchase the vehicle for the full price the customer paid for it (not exceeding the fair market value at the time the customer purchased it), including taxes and fees, if the vehicle is returned to General Motor's possession by January 31, 2007. There will be no deductions for mileage or use unless the vehicle has sustained substantial damage beyond normal wear and tear. General Motors reserves the right to handle each transaction on a case-by-case basis relative to the application of a reasonable depreciation allowance for mileage or use and/or reduction in repurchase price if the vehicle has sustained substantial damage beyond normal wear and tear. General Motors will also pay for the removal of any aftermarket accessories the customer may have installed before they were notified of this recall and return them to the customer. If they no longer have a use for those accessories or they cannot be removed, General Motors will reimburse the customer for the purchase price of those accessories. The customer's local GM dealer will contact General Motors to begin the repurchase process. General Motors will work with the customer to reach an agreement on the purchase of the vehicle. Dealers will be asked by General Motors to assist in the removal of any aftermarket accessories, inspection of the vehicle, obtaining titles and other documentation required to transfer ownership to General Motors, presenting the customer with a check for the purchase, and taking possession of the vehicle. General Motors will arrange for transportation of the vehicle from the dealer. If any of these vehicles are in the used car inventory of your dealership or were sold by you, or a customer brings in an involved vehicle for service, please contact the GM Reacquired Vehicle Disclosure Center (RVCD). If any of these vehicles are in the used car inventory of your dealership or were sold by you, please contact General Motors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Recalls: > 06102B > Oct > 07 > Recall - Aftermarket Leather Seat Cover Kit > Page 15474 Vehicles Involved For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the GM DealerWorld Recall Information system. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information No parts are required for this recall. Service Procedure General Motors will work with the customer to reach an agreement on the purchase of the vehicle. Dealers will be asked by General Motors to assist in the removal of any aftermarket accessories, inspection of the vehicle, obtaining titles and other documentation required to transfer ownership to General Motors, presenting the customer with a check for the repurchase, and taking possession of the vehicle. General Motors will arrange for transportation of the vehicle from the dealer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Recalls: > 06102B > Oct > 07 > Recall - Aftermarket Leather Seat Cover Kit > Page 15475 If any of the involved vehicles are in the used car inventory of your dealership or were recently sold by you or a customer brings in an involved vehicle for service, please contact the GM Reacquired Vehicle Disclosure Center (RVDC). Claim Information Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Dealer Recall Responsibility The customer will contact General Motors to begin the repurchase process. General Motors will work with the customer to reach an agreement on the purchase of the vehicle. Dealers will be contacted by General Motors to assist in the removal of any aftermarket accessories, inspection of the vehicle, obtaining titles and other documentation required to transfer ownership to General Motors, presenting the customer with a check for the purchase, and taking possession of the vehicle. General Motors will arrange for transportation of the vehicle from the dealer. Whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must contact the GM Reacquired Vehicle Disclosure Center (RVDC). Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Recalls: > 06102B > Oct > 07 > Recall - Aftermarket Leather Seat Cover Kit > Page 15476 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Recalls: > 06102B > Oct > 07 > Recall - Aftermarket Leather Seat Cover Kit > Page 15477 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Recalls: > 06102B > Oct > 07 > Recall - Aftermarket Leather Seat Cover Kit > Page 15478 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 04-08-50-006D > Sep > 10 > Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: All Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 04-08-50-006D > Sep > 10 > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 15484 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 04-08-50-006D > Sep > 10 > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 15485 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 00-00-89-027E > Sep > 08 > Interior - Elimination Of Unwanted Odors Seat Cover: All Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 00-00-89-027E > Sep > 08 > Interior - Elimination Of Unwanted Odors > Page 15490 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 00-00-89-027E > Sep > 08 > Interior - Elimination Of Unwanted Odors > Page 15491 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 06102B > Oct > 07 > Recall - Aftermarket Leather Seat Cover Kit Technical Service Bulletin # 06102B Date: 071019 Recall - Aftermarket Leather Seat Cover Kit Subject: Product Safety - Aftermarket Leather Seat Cover Kits # 06102B - (10/19/2007) 2005-2006 Buick LaCrosse, Rendezvous 2004 Chevrolet Silverado 2005 Chevrolet Tahoe 2005-2006 Chevrolet TrailBlazer, TrailBlazer EXT 2006 Chevrolet HHR, Malibu 2005 GMC Sierra 2005-2006 GMC Envoy 2006 GMC Envoy XL 2006 HUMMER H3 2005 Pontiac Montana 2006 Pontiac G6 The telephone number for contacting General Motors has been changed. To assist customers with initiating the vehicle repurchase process, dealers should contact the GM Reacquired Vehicle Disclosure Center (RVDC). With dealer assistance, the RVDC will work with the customer to reach an agreement on the purchase and physical transfer of the vehicle. Condition General Motors has decided that a defect that relates to motor vehicle safety exists in aftermarket front passenger leather cover kits that were installed at its request on certain vehicles with the Passenger Sensing System. Recently, testing on these seat covers indicated that they can cause the Passenger Sensing system to malfunction. If the Passenger Sensing System malfunctions, the front airbag on the passenger side may be disabled when it should be enabled, or enabled when it should be disabled. In either case, in the event of a crash that requires airbag deployment, a front passenger's level of injury may be increased. The airbag status indicator displays the status of the airbag. Whenever the front passenger seat is occupied, the driver should always check the airbag indicator to see if the airbag is on or off as explained in the owner manual. If it is not correct for the situation, the passenger should be moved to a different seat. Correction Because a replacement leather seat cover that is compatible with the Passenger Sensing System is not available, General Motors will repurchase the vehicle for the full price the customer paid for it (not exceeding the fair market value at the time the customer purchased it), including taxes and fees, if the vehicle is returned to General Motor's possession by January 31, 2007. There will be no deductions for mileage or use unless the vehicle has sustained substantial damage beyond normal wear and tear. General Motors reserves the right to handle each transaction on a case-by-case basis relative to the application of a reasonable depreciation allowance for mileage or use and/or reduction in repurchase price if the vehicle has sustained substantial damage beyond normal wear and tear. General Motors will also pay for the removal of any aftermarket accessories the customer may have installed before they were notified of this recall and return them to the customer. If they no longer have a use for those accessories or they cannot be removed, General Motors will reimburse the customer for the purchase price of those accessories. The customer's local GM dealer will contact General Motors to begin the repurchase process. General Motors will work with the customer to reach an agreement on the purchase of the vehicle. Dealers will be asked by General Motors to assist in the removal of any aftermarket accessories, inspection of the vehicle, obtaining titles and other documentation required to transfer ownership to General Motors, presenting the customer with a check for the purchase, and taking possession of the vehicle. General Motors will arrange for transportation of the vehicle from the dealer. If any of these vehicles are in the used car inventory of your dealership or were sold by you, or a customer brings in an involved vehicle for service, please contact the GM Reacquired Vehicle Disclosure Center (RVCD). If any of these vehicles are in the used car inventory of your dealership or were sold by you, please contact General Motors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 06102B > Oct > 07 > Recall - Aftermarket Leather Seat Cover Kit > Page 15496 Vehicles Involved For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the GM DealerWorld Recall Information system. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information No parts are required for this recall. Service Procedure General Motors will work with the customer to reach an agreement on the purchase of the vehicle. Dealers will be asked by General Motors to assist in the removal of any aftermarket accessories, inspection of the vehicle, obtaining titles and other documentation required to transfer ownership to General Motors, presenting the customer with a check for the repurchase, and taking possession of the vehicle. General Motors will arrange for transportation of the vehicle from the dealer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 06102B > Oct > 07 > Recall - Aftermarket Leather Seat Cover Kit > Page 15497 If any of the involved vehicles are in the used car inventory of your dealership or were recently sold by you or a customer brings in an involved vehicle for service, please contact the GM Reacquired Vehicle Disclosure Center (RVDC). Claim Information Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Dealer Recall Responsibility The customer will contact General Motors to begin the repurchase process. General Motors will work with the customer to reach an agreement on the purchase of the vehicle. Dealers will be contacted by General Motors to assist in the removal of any aftermarket accessories, inspection of the vehicle, obtaining titles and other documentation required to transfer ownership to General Motors, presenting the customer with a check for the purchase, and taking possession of the vehicle. General Motors will arrange for transportation of the vehicle from the dealer. Whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must contact the GM Reacquired Vehicle Disclosure Center (RVDC). Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 06102B > Oct > 07 > Recall - Aftermarket Leather Seat Cover Kit > Page 15498 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 06102B > Oct > 07 > Recall - Aftermarket Leather Seat Cover Kit > Page 15499 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 06102B > Oct > 07 > Recall - Aftermarket Leather Seat Cover Kit > Page 15500 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 04-08-50-011A > May > 06 > Interior - Napped Seat Fabric Repair Seat Cover: All Technical Service Bulletins Interior - Napped Seat Fabric Repair Bulletin No.: 04-08-50-011A Date: May 04, 2006 INFORMATION Subject: Repairing Napped Seat Fabric Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 1999-2006 Chevrolet Silverado 2000-2007 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Astro 2002-2006 Chevrolet Monte Carlo 2002-2007 Chevrolet Avalanche 2002-2005 GMC Safari 2007 GMC Yukon, Yukon XL 2002-2004 Oldsmobile Alero 1997-2006 Pontiac Grand Prix Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 04-08-50-011 (Section 08 - Body & Accessories). This bulletin is being issued to advise technicians/dealers on the proper repair required when a customer brings in a trimmed seat with the appearance of being worn, having a bald spot and/or being discolored. The seats in the later vehicles are trimmed with a cloth that has a napped fabric. Under some circumstances, the nap may become crushed down by normal use, giving the appearance of being worn out. If the base material is NOT visible, use a small brass (NOT STEEL) wire brush to carefully fluff and raise the nap. The wire brush (fine bristle brass) is available at most hardware and home stores. If the base material is visible, replace the trim cover. The Astro/Safari van will also have this material on the door trim. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 04-08-50-006D > Sep > 10 > Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: All Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 04-08-50-006D > Sep > 10 > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 15510 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 04-08-50-006D > Sep > 10 > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 15511 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 00-00-89-027E > Sep > 08 > Interior - Elimination Of Unwanted Odors Seat Cover: All Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 00-00-89-027E > Sep > 08 > Interior - Elimination Of Unwanted Odors > Page 15516 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 00-00-89-027E > Sep > 08 > Interior - Elimination Of Unwanted Odors > Page 15517 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 04-08-50-011A > May > 06 > Interior - Napped Seat Fabric Repair Seat Cover: All Technical Service Bulletins Interior - Napped Seat Fabric Repair Bulletin No.: 04-08-50-011A Date: May 04, 2006 INFORMATION Subject: Repairing Napped Seat Fabric Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 1999-2006 Chevrolet Silverado 2000-2007 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Astro 2002-2006 Chevrolet Monte Carlo 2002-2007 Chevrolet Avalanche 2002-2005 GMC Safari 2007 GMC Yukon, Yukon XL 2002-2004 Oldsmobile Alero 1997-2006 Pontiac Grand Prix Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 04-08-50-011 (Section 08 - Body & Accessories). This bulletin is being issued to advise technicians/dealers on the proper repair required when a customer brings in a trimmed seat with the appearance of being worn, having a bald spot and/or being discolored. The seats in the later vehicles are trimmed with a cloth that has a napped fabric. Under some circumstances, the nap may become crushed down by normal use, giving the appearance of being worn out. If the base material is NOT visible, use a small brass (NOT STEEL) wire brush to carefully fluff and raise the nap. The wire brush (fine bristle brass) is available at most hardware and home stores. If the base material is visible, replace the trim cover. The Astro/Safari van will also have this material on the door trim. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Page 15522 Seat Cover: Service and Repair Seat Back Cover and Pad Replacement - Rear Removal Procedure 1. Remove the rear seat from the vehicle. 2. Remove the seat back folding cover, if equipped. 3. Remove the armrest from the seat back, if equipped. 4. Remove the head restraints (1) from the seat back. 5. Release the J-clips from the seat back cover. 6. Release the hook, and the loop strips retaining the seat back cover (2) to the foam pad (12). 7. In order to ease removal, place a piece of cardboard between the seat back cover and the foam pad. 8. Working from side to side, carefully lift the seat back cover from the foam pad. Installation Procedure 1. Working from side to side, carefully install the seat back cover over the foam pad. 2. Remove the cardboard from between the seat back cover and the foam pad. 3. Engage the hook, and the loop strips that retain the seat back cover (2). 4. Engage the J-clips that retain the seat back cover. 5. Install the head restraints (1) to the seat back. 6. Install the armrest to the seat back, if removed. 7. Install the seat back folding cover, if removed. 8. Install the rear seat to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures Seat Cushion: Procedures Seat Cushion Frame Replacement - Front SEAT CUSHION FRAME REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the seat trim panel. 2. Remove the seat cushion trim cover and pad. 3. Remove the following components from the seat cushion frame: - The frame springs (1) - The frame suspension (2) - The plastic retainers (3) 4. Remove the seat cushion frame from the vehicle. INSTALLATION PROCEDURE 1. Install the following components to the seat cushion frame: - The plastic retainers (3) - The frame suspension (2) - The frame springs (1) 2. Install the seat cushion trim cover and pad. 3. Install the seat trim panel. 4. Re-zero the inflatable restraint passenger presence system. Refer to Passenger Presence System Rezeroing Procedure in Restraint Systems. Seat Cushion Cover and Pad Replacement - Rear SEAT CUSHION COVER AND PAD REPLACEMENT - REAR REMOVAL PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15527 1. Remove the rear seat from the vehicle. 2. Remove the rear passenger seat riser. 3. Remove the hog rings and/or the J-clips from the rear edge of the seat cushion cover (3). 4. Disconnect the rear heater connector, if equipped. 5. Remove the seat belt buckles, if required. 6. Remove all of the remaining hog rings, and/or the J-clips that are retaining the seat cushion cover (3) to the seat cushion frame (8). 7. Release the hook, and the loop-strips that are retaining the seat cushion cover to the foam pad (4). 8. Remove the center screw retaining the latch cover, if equipped. 9. Remove the seat cushion cover from the foam pad. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15528 1. Install the seat cushion cover to the foam pad. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the center screw retaining the latch cover, if removed. Tighten Tighten the screw to 2 N.m (18 lb in). 3. Engage the hook, and the loop-strips that are retaining the seat cushion cover (3) to the foam pad (4). 4. Install the seat buckles, if removed. 5. Connect the rear heater connector, if equipped. 6. Install the hog rings, and/or the J-clips in order to retain the seat cushion cover to the seat cushion frame (8). 7. Install the rear passenger seat risers. 8. Install the rear seat to the vehicle. Seat Cushion Trim Cover and Pad Replacement SEAT CUSHION TRIM COVER AND PAD REPLACEMENT REMOVAL PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15529 1. Remove the front nuts (2) on the underside of the seat cushion. 2. Remove the front seat trim panel. 3. Unsnap the lumbar cable (6). Disconnect the lumbar wire harness if equipped with power lumbar. 4. Disconnect the electrical connectors. 5. Remove the pressure sensor (2) from the front passenger seat frame, if equipped with the Inflatable Restraint Passenger Presence System. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15530 6. Lift the seat cushion up off the rear plastic holders (1) on the underside of the seat cushion, and pull forward. 7. Remove the seat switch bezel. 8. Remove the lumbar actuator (5). 9. Unclip the seat trim cover from the seat cushion frame. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15531 10. Using a side motion, carefully separate the seat cushion trim cover from the seat cushion pad. CAUTION: Replace the passenger presence system as a complete assembly to prevent possible injury to the occupant. The bladder, the pressure sensor, the seat cushion, and the control module are assembled and calibrated as a unit. Using only some of the components in the service kit will cause the passenger presence system to operate improperly. 11. If replacing the front passenger seat cushion you must also replace the Inflatable Restraint Passenger Presence System. 12. Remove the pad from the seat cushion frame. 13. Remove the seat cushion heater element, if equipped. INSTALLATION PROCEDURE 1. Install the seat cushion heater element, if equipped. 2. Install the Inflatable Restraint Passenger Presence System. 3. Install the seat cushion pad to the seat cushion frame. 4. Using a side motion, carefully pull the seat cushion cover onto the frame pad. 5. Attach the seat trim cover to the seat cushion frame. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15532 6. Install the lumbar actuator (5). 7. Install the seat switch bezel. 8. Place the cushion on the rear plastic holders (1) on the underside of the seat cushion, and push rearward. 9. Connect the lumbar cable to the underside of the seat cushion (6). Connect the lumbar wire harness, if equipped with power lumbar. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15533 10. Install the pressure sensor (2) to the front passenger seat frame, if equipped with the Inflatable Restraint Passenger Presence System. 11. Connect the electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. 12. Install the front nuts (2) onto the studs on the underside of the cushion. Tighten Tighten the nuts to 21 N.m (15 lb ft). 13. Install the front seat trim panel. 14. Re-zero the Inflatable Restraint Passenger Presence System. Refer to Passenger Presence System Rezeroing Procedure in Restraint Systems. Seat Cushion Frame Replacement - Rear SEAT CUSHION FRAME REPLACEMENT - REAR REMOVAL PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15534 1. Remove the seat cushion trim cover (8) and the pad (7). 2. Remove the bolts from the hinge assembly, if equipped with folding seats. 3. Remove the seat cushion frame (5). INSTALLATION PROCEDURE 1. Install the seat cushion frame (5). NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15535 2. Install the bolts to the hinge assembly, if removed. Tighten Tighten the bolts to 35 N.m (26 lb ft). 3. Install the seat cushion trim cover (8) and the pad (7). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15536 Seat Cushion: Removal and Replacement Seat Cushion Cover and Pad Replacement - Rear Seat Cushion Cover and Pad Replacement - Rear Removal Procedure 1. Remove the rear seat from the vehicle. 2. Remove the rear passenger seat riser. 3. Remove the hog rings and/or the J-clips from the rear edge of the seat cushion cover (3). 4. Disconnect the rear heater connector, if equipped. 5. Remove the seat belt buckles, if required. 6. Remove all of the remaining hog rings, and/or the J-clips that are retaining the seat cushion cover (3) to the seat cushion frame (8). 7. Release the hook, and the loop-strips that are retaining the seat cushion cover to the foam pad (4). 8. Remove the center screw retaining the latch cover, if equipped. 9. Remove the seat cushion cover from the foam pad. Installation Procedure 1. Install the seat cushion cover to the foam pad. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the center screw retaining the latch cover, if removed. Tighten the screw to 2 N.m (18 lb in). 3. Engage the hook, and the loop-strips that are retaining the seat cushion cover (3) to the foam pad (4). 4. Install the seat buckles, if removed. 5. Connect the rear heater connector, if equipped. 6. Install the hog rings, and/or the J-clips in order to retain the seat cushion cover to the seat cushion frame (8). 7. Install the rear passenger seat risers. 8. Install the rear seat to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15537 Seat Cushion Frame Replacement - Front Seat Cushion Frame Replacement - Front Removal Procedure 1. Remove the seat trim panel. 2. Remove the seat cushion trim cover and pad. 3. Remove the following components from the seat cushion frame: * The frame springs (1) * The frame suspension (2) * The plastic retainers (3) 4. Remove the seat cushion frame from the vehicle. Installation Procedure 1. Install the following components to the seat cushion frame: * The plastic retainers (3) * The frame suspension (2) * The frame springs (1) 2. Install the seat cushion trim cover and pad. 3. Install the seat trim panel. 4. Re-zero the inflatable restraint passenger presence system. Refer to Passenger Presence System Rezeroing Procedure in SIR. See: Restraint Systems/Air Bag Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Related Tests and Procedures/Passenger Presence System Rezeroing Procedure Seat Cushion Frame Replacement - Rear Seat Cushion Frame Replacement - Rear Removal Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15538 1. Remove the seat cushion trim cover (8) and the pad (7). 2. Remove the bolts from the hinge assembly, if equipped with folding seats. 3. Remove the seat cushion frame (5). Installation Procedure 1. Install the seat cushion frame (5). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the hinge assembly, if removed. Tighten the bolts to 35 N.m (26 lb ft). 3. Install the seat cushion trim cover (8) and the pad (7). Seat Cushion Trim Cover and Pad Replacement Seat Cushion Trim Cover and Pad Replacement Removal Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15539 1. Remove the front nuts (2) on the underside of the seat cushion. 2. Remove the front seat trim panel. 3. Unsnap the lumbar cable (6). Disconnect the lumbar wire harness if equipped with power lumbar. 4. Disconnect the electrical connectors. 5. Remove the pressure sensor (2) from the front passenger seat frame, if equipped with the Inflatable Restraint Passenger Presence System. 6. Lift the seat cushion up off the rear plastic holders (1) on the underside of the seat cushion, and pull forward. 7. Remove the seat switch bezel. 8. Remove the lumbar actuator (5). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15540 9. Unclip the seat trim cover from the seat cushion frame. 10. Using a side motion, carefully separate the seat cushion trim cover from the seat cushion pad. Caution: Replace the passenger presence system as a complete assembly to prevent possible injury to the occupant. The bladder, the pressure sensor, the seat cushion, and the control module are assembled and calibrated as a unit. Using only some of the components in the service kit will cause the passenger presence system to operate improperly. 11. If replacing the front passenger seat cushion you must also replace the Inflatable Restraint Passenger Presence System. Refer to Inflatable Restraint Passenger Presence System Replacement - Front in SIR. 12. Remove the pad from the seat cushion frame. 13. Remove the seat cushion heater element, if equipped. Installation Procedure 1. Install the seat cushion heater element, if equipped. 2. Install the Inflatable Restraint Passenger Presence System. 3. Install the seat cushion pad to the seat cushion frame. 4. Using a side motion, carefully pull the seat cushion cover onto the frame pad. 5. Attach the seat trim cover to the seat cushion frame. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15541 6. Install the lumbar actuator (5). 7. Install the seat switch bezel. 8. Place the cushion on the rear plastic holders (1) on the underside of the seat cushion, and push rearward. 9. Connect the lumbar cable to the underside of the seat cushion (6). Connect the lumbar wire harness, if equipped with power lumbar. 10. Install the pressure sensor (2) to the front passenger seat frame, if equipped with the Inflatable Restraint Passenger Presence System. 11. Connect the electrical connectors. Notice: Refer to Fastener Notice in Service Precautions. 12. Install the front nuts (2) onto the studs on the underside of the cushion. Tighten the nuts to 21 N.m (15 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 15542 13. Install the front seat trim panel. 14. Re-zero the Inflatable Restraint Passenger Presence System. Refer to Passenger Presence System Rezeroing. See: Restraint Systems/Air Bag Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Related Tests and Procedures/Passenger Presence System Rezeroing Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 05-08-50-008 > Aug > 05 > Interior - Intermittent Seat Heater Operation Seat Heater: Customer Interest Interior - Intermittent Seat Heater Operation Bulletin No.: 05-08-50-008 Date: August 19, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 05-08-05-008 > Aug > 05 > Interior - Heated Seats Intermittently Inoperative Seat Heater: Customer Interest Interior - Heated Seats Intermittently Inoperative Bulletin No.: 05-08-05-008 Date: August 18, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 05-08-50-008 > Aug > 05 > Interior - Intermittent Seat Heater Operation Seat Heater: All Technical Service Bulletins Interior - Intermittent Seat Heater Operation Bulletin No.: 05-08-50-008 Date: August 19, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 05-08-05-008 > Aug > 05 > Interior - Heated Seats Intermittently Inoperative Seat Heater: All Technical Service Bulletins Interior - Heated Seats Intermittently Inoperative Bulletin No.: 05-08-05-008 Date: August 18, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Page 15564 Seat Heater: Diagrams Heated Seat Element - Driver Cushion Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Page 15565 Heated Seat Element - Front Passenger Cushion Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Page 15566 Seat Heater: Description and Operation HEATED SEATS DESCRIPTION AND OPERATION HEATED SEAT COMPONENTS The heated seat system consists of the following components: Driver and passenger heated seat switches - Driver and passenger seat back heater elements - Driver and passenger seat cushion heater elements - Driver and passenger seat back temperature sensors - Driver seat module - Driver door module - Passenger door module HEATED SEAT SYSTEM OPERATION The driver and passenger heated seats have 2 heat zone operating modes with 3 heat level modes and will operate only while the engine is running. The heat zones are determined by which of the 2 heated seat buttons are pressed, while the heat level is determined by the number of times they are pressed. Pressing the seat cushion button 1 time will activate the seat back and cushion heater elements in the high mode. Each time the seat cushion button is pressed the seat back and cushion heat level is reduced from high to medium, low, and off. Pressing the heated seat back button 1 time will activate only the seat back heater element in the high mode. Each time the seat back button is pressed the seat back heat level is reduced from high to medium, low, and off. During heated seat operation the heat zone operating mode may be changed without affecting the current heat level mode. The heated seat switches are momentary contact switches and are inputs to the driver and passenger door modules. Battery voltage is supplied to the switch assembly from the door module, and when a heated seat switch is pressed and released a brief switch signal voltage is supplied to the door module. Whenever the door module receives an active heated seat switch input, the next heated seat operating mode is determined by whatever the current mode may be. The seat heater elements are controlled by the driver seat module using inputs from the door modules through Class 2 serial data circuit messages. The driver seat module controls the voltage supply and the ground circuits to the seat heater elements. When a heated seat function is commanded active, the seat module will switch battery voltage to the heater element supply circuits, and ground is provided through low side drive control circuits. During heated seat operation both the seat back and cushion heater elements are supplied battery voltage. The seat module grounds the appropriate control circuits for back only or back and cushion heating modes, and opens or closes the active control circuits as necessary in order to maintain the desired seat temperature. The seat module relies on inputs from thermistors located in the driver and passenger seat backs to control heated seat temperatures. The thermistors are 2 wire sensors supplied with a 5-voltreferenced signal circuit and a low reference circuit from the seat module. Resistance through the thermistors varies with temperature causing the heated seat sensor signal circuit voltage levels to decrease as the seat back temperatures rise. The seat modules allow heated seat operation only while the engine is running which is determined by a Class 2 serial data circuit message from the powertrain control module. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Procedures Seat Heater: Procedures Seat Back Heater Element Replacement - Front SEAT BACK HEATER ELEMENT REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the seat from the vehicle. 2. Remove the seat back trim cover. 3. Peel the seat back heater off the foam pad. 4. Disconnect the seat back heater harness. INSTALLATION PROCEDURE 1. Connect the seat back heater harness. 2. Install the seat back heater. 3. Install the seat back trim cover. 4. Install the seat in the vehicle. Seat Cushion Heater Element Replacement - Front SEAT CUSHION HEATER ELEMENT REPLACEMENT - FRONT REMOVAL PROCEDURE CAUTION: If the passenger seat cushion foam is damaged when you remove the heater element, replace the passenger pressence system in order to prevent personal injury. 1. Remove the seat trim panel. 2. Remove the seat cushion trim cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Procedures > Page 15569 3. Peel the seat cushion heater off of the pad. 4. Disconnect the seat cushion heater wiring harness. INSTALLATION PROCEDURE 1. Replace the inflatable restraint passenger presence system if the passenger seat cushion foam is damaged. 2. Connect the cushion heater wiring harness. 3. Install the seat cushion heater. 4. Install the seat cushion trim cover. 5. Install the seat trim panel. 6. Re-zero the inflatable restraint passenger presence system for the front passenger seat. Refer to Passenger Presence System Rezeroing Procedure in Restraint Systems. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Procedures > Page 15570 Seat Heater: Removal and Replacement Seat Cushion Heater Element Replacement - Front Removal Procedure Caution: If the passenger seat cushion foam is damaged when you remove the heater element, replace the passenger pressence system in order to prevent personal injury. 1. Remove the seat trim panel. 2. Remove the seat cushion trim cover. 3. Peel the seat cushion heater off of the pad. 4. Disconnect the seat cushion heater wiring harness. Installation Procedure 1. Replace the inflatable restraint passenger presence system if the passenger seat cushion foam is damaged. 2. Connect the cushion heater wiring harness. 3. Install the seat cushion heater. 4. Install the seat cushion trim cover. 5. Install the seat trim panel. 6. Re-zero the inflatable restraint passenger presence system for the front passenger seat. Refer to Passenger Presence System Rezeroing Procedure. See: Restraint Systems/Air Bag Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Related Tests and Procedures/Passenger Presence System Rezeroing Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 05-08-50-008 > Aug > 05 > Interior Intermittent Seat Heater Operation Seat Heater Control Module: Customer Interest Interior - Intermittent Seat Heater Operation Bulletin No.: 05-08-50-008 Date: August 19, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 05-08-05-008 > Aug > 05 > Interior Heated Seats Intermittently Inoperative Seat Heater Control Module: Customer Interest Interior - Heated Seats Intermittently Inoperative Bulletin No.: 05-08-05-008 Date: August 18, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 05-08-50-008 > Aug > 05 > Interior - Intermittent Seat Heater Operation Seat Heater Control Module: All Technical Service Bulletins Interior - Intermittent Seat Heater Operation Bulletin No.: 05-08-50-008 Date: August 19, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 05-08-05-008 > Aug > 05 > Interior - Heated Seats Intermittently Inoperative Seat Heater Control Module: All Technical Service Bulletins Interior - Heated Seats Intermittently Inoperative Bulletin No.: 05-08-05-008 Date: August 18, 2005 TECHNICAL Subject: Intermittent Heated Seats Inoperative, DTC B3941 Set (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Condition Some customers may comment that occasionally the seat heater will not operate when activated. If the ignition key is cycled OFF and back ON again, the heated seat will operate correctly. Also, on some LB7 diesel engine vehicles, the seat heater may turn itself off during the first 10 minutes of operation. This occurs only with the first activation for the day and works correctly with subsequent activations immediately after the event. These conditions are intermiffent and DTC B3941 may be set. Correction Technicians are to reprogram the driver seat module with an updated software calibration. This new service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 04-08-50-007 > Mar > 04 > Interior - Front Heated Seat(s) Inoperative Seat Heater Switch: Customer Interest Interior - Front Heated Seat(s) Inoperative Bulletin No.: 04-08-50-007 Date: March 12, 2004 INFORMATION Subject: Service Information for Front Heated Seat Inoperative/Cold Models: 2003-2004 Cadillac Escalade/ESV/EXT 2003-2004 Chevrolet Avalanch/Silverado/Suburban/Tahoe 2003-2004 GMC Denali/Sierra/Yukon/Yukon XL 2003-2004 Hummer H2 The purpose of this bulletin is to provide the technician with the following service information: ^ Heated Seats Switch Operation ^ Heated Seats Switch Diagnostics ^ Heated Seats Switch Customer Information Switch Operation 1. The engine must be running for the heated seat feature to work. The heated seats will shut off automatically when the ignition is turned off. 2. Two buttons, located on the door, are used to control the heated seat. ^ Press the horizontal (RH) button to heat the entire seat, back and cushion. ^ Press the vertical (LH) button to heat ONLY the seat back. ^ The three light bars are an indicator of the level of heat selected for either the entire seat (horizontal button) or ONLY the seat back (vertical button). 3. To heat both the seat back and seat cushion at the same time, press the horizontal (RH) button with the heated seat symbol one time. ^ All 3 light bars will glow indicating the HIGH temperature setting. ^ The horizontal (RH) button does NOT have an ON/OFF indicator light. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 04-08-50-007 > Mar > 04 > Interior - Front Heated Seat(s) Inoperative > Page 15600 4. Press the button a second time, 2 light bars will glow indicating the MEDIUM temperature setting for the entire seat. 5. Press the button a third time, 1 light bar will glow indicating the LOW temperature setting for the entire seat. 6. Press the button a fourth time to turn the entire heated seat OFF. 7. To heat ONLY the seat back, press the vertical (LH) button one time. ^ An ON/OFF indicator light over the heated seat back symbol will glow to designate that ONLY the seat back is being heated. ^ All 3 light bars over the horizontal (RH) button will glow indicating the HIGH temperature setting for ONLY the seat back. 8. Press the button a second time, 2 light bars will glow indicating the MEDIUM temperature setting for ONLY the seat back. 9. Press the button a third time, 1 light bar will glow indicating the LOW temperature setting for ONLY the seat back. 10. Press the button a fourth time to turn the heated seat back OFF. Switch Diagnostics Important: In order to eliminate unnecessary part replacement and comeback repairs, it is essential that the appropriate diagnostic tables and aids found in the applicable manuals are followed. 1. Verify the condition prior to making any repairs. Refer to Seats and Seat Controls in the applicable Owners Manual or this bulletin for proper heated seat switch operation information. 2. If an improperly operating front heated seat condition exists, refer to the Diagnostic Information and Procedures in the Seats sub-section of the applicable Service Manual in order to diagnose the system accurately. 3. When measuring the resistance of the seat heater elements, ensure the values are within the updated range of 1.5-5.5 ohms. Refer to DTC B2425 or B2430-Clearing the DTC in the Diagnostic Information and Procedures in the Seats sub-section of the applicable Service Manual. Customer Information Some heated seat components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) for heat function not operating properly. Analyses of these parts show 'no out of specification condition' or No Trouble Found (NTF). 1. Provide customers with the knowledge that if bumped, either one of the heated seat switches can be activated/deactivated accidentally. 2. Ensure customers have a thorough understanding of how the heated seat switches function. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 04-08-50-007 > Mar > 04 > Interior - Front Heated Seat(s) Inoperative Seat Heater Switch: All Technical Service Bulletins Interior - Front Heated Seat(s) Inoperative Bulletin No.: 04-08-50-007 Date: March 12, 2004 INFORMATION Subject: Service Information for Front Heated Seat Inoperative/Cold Models: 2003-2004 Cadillac Escalade/ESV/EXT 2003-2004 Chevrolet Avalanch/Silverado/Suburban/Tahoe 2003-2004 GMC Denali/Sierra/Yukon/Yukon XL 2003-2004 Hummer H2 The purpose of this bulletin is to provide the technician with the following service information: ^ Heated Seats Switch Operation ^ Heated Seats Switch Diagnostics ^ Heated Seats Switch Customer Information Switch Operation 1. The engine must be running for the heated seat feature to work. The heated seats will shut off automatically when the ignition is turned off. 2. Two buttons, located on the door, are used to control the heated seat. ^ Press the horizontal (RH) button to heat the entire seat, back and cushion. ^ Press the vertical (LH) button to heat ONLY the seat back. ^ The three light bars are an indicator of the level of heat selected for either the entire seat (horizontal button) or ONLY the seat back (vertical button). 3. To heat both the seat back and seat cushion at the same time, press the horizontal (RH) button with the heated seat symbol one time. ^ All 3 light bars will glow indicating the HIGH temperature setting. ^ The horizontal (RH) button does NOT have an ON/OFF indicator light. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 04-08-50-007 > Mar > 04 > Interior - Front Heated Seat(s) Inoperative > Page 15606 4. Press the button a second time, 2 light bars will glow indicating the MEDIUM temperature setting for the entire seat. 5. Press the button a third time, 1 light bar will glow indicating the LOW temperature setting for the entire seat. 6. Press the button a fourth time to turn the entire heated seat OFF. 7. To heat ONLY the seat back, press the vertical (LH) button one time. ^ An ON/OFF indicator light over the heated seat back symbol will glow to designate that ONLY the seat back is being heated. ^ All 3 light bars over the horizontal (RH) button will glow indicating the HIGH temperature setting for ONLY the seat back. 8. Press the button a second time, 2 light bars will glow indicating the MEDIUM temperature setting for ONLY the seat back. 9. Press the button a third time, 1 light bar will glow indicating the LOW temperature setting for ONLY the seat back. 10. Press the button a fourth time to turn the heated seat back OFF. Switch Diagnostics Important: In order to eliminate unnecessary part replacement and comeback repairs, it is essential that the appropriate diagnostic tables and aids found in the applicable manuals are followed. 1. Verify the condition prior to making any repairs. Refer to Seats and Seat Controls in the applicable Owners Manual or this bulletin for proper heated seat switch operation information. 2. If an improperly operating front heated seat condition exists, refer to the Diagnostic Information and Procedures in the Seats sub-section of the applicable Service Manual in order to diagnose the system accurately. 3. When measuring the resistance of the seat heater elements, ensure the values are within the updated range of 1.5-5.5 ohms. Refer to DTC B2425 or B2430-Clearing the DTC in the Diagnostic Information and Procedures in the Seats sub-section of the applicable Service Manual. Customer Information Some heated seat components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) for heat function not operating properly. Analyses of these parts show 'no out of specification condition' or No Trouble Found (NTF). 1. Provide customers with the knowledge that if bumped, either one of the heated seat switches can be activated/deactivated accidentally. 2. Ensure customers have a thorough understanding of how the heated seat switches function. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > Page 15607 Seat Heater Switch: Locations Driver Door Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > Page 15608 Front Passenger Door Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > Page 15609 Seat Heater Switch: Diagrams Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > Page 15610 Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > Page 15611 Front Passenger Door Module (FPDM) - C5 (Heated Seat Switch) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > Page 15612 Heated Seat Switch - Front Passenger (FPDM C5) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > Page 15613 Memory/Heated Seat Switch - Driver (DDM C5) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > Page 15614 Memory/Heated Seat Switch - Driver (DDM C5) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch Replacement - Front Seat Heater Switch: Service and Repair Heated Seat Switch Replacement - Front HEATED SEAT SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connector. 3. Release the retaining clips for the front seat heater switch assembly in order to remove the switch. 4. Remove the front seat heater switch assembly. INSTALLATION PROCEDURE 1. Install the front seat heater switch assembly to the front trim panel by pressing the switch into place until the switch is completely seated. 2. Connect the electrical connector to the front seat heater switch assembly. 3. Install the front trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch Replacement - Front > Page 15617 Seat Heater Switch: Service and Repair Heated Seat Switch Replacement - Rear HEATED SEAT SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the center console end panel. 2. Disconnect the electrical connector. 3. Remove the seat heater switch retaining screws. 4. Remove the switch from the vehicle. INSTALLATION PROCEDURE 1. Install the switch to the console panel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screw. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector. 4. Install the center console end panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 05-08-50-012A > Jul > 06 > Interior - Loose/Unwanted Seat Movement Seat Track: Customer Interest Interior - Loose/Unwanted Seat Movement Bulletin No.: 05-08-50-012A Date: July 24, 2006 TECHNICAL Subject: Unwanted/Loose Seat Movement (Apply Adhesive and Install New Bolts in Seat Mounting Rails) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac ESV 1999-2007 Chevrolet Silverado Pickup Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Pickup Models (Classic) 2000-2006 GMC Yukon, Yukon XL 2003-2006 HUMMER H2 with Power Driver Front Seat Power Adjuster (RPO AG1) and/or Passenger Seat Power Adjuster (RPO AG2) Supercede: This bulletin is being revised to add model years and additional Warranty Information. Please discard Corporate Bulletin Number 05-08-50-012 (Section 08 - Body and Accessories). Condition Some customers may comment on unwanted seat movement in the front power bucket seat (driver or passenger) during fast acceleration or hard braking. A metal to metal clicking noise is often heard at seat "stops." Cause The threads of the two zinc nut retainers (one on each side of the seat adjuster) may creep over time, causing a loss of self-rolling screw clamp load and ultimately causes relative rail and vehicle seat motion. Correction Apply adhesive and install new bolts in seat mounting rails using the following procedure. 1. Remove the front seat and invert onto a flat surface covered with a clean, non-scratch material (soft cloth or similar). Refer to the applicable Seats sub-section in SI. Adjust so that the seat mounting rails are at 45 degrees. 2. Remove the upper M8 mounting bolt from one rail and discard. Leave the other bolt intact as this will hold the track in place while working. Wipe the bolt hole area with a clean rag. Important: Only use the adhesive provided in the repair kit. Do not substitute with other adhesives. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 05-08-50-012A > Jul > 06 > Interior - Loose/Unwanted Seat Movement > Page 15626 3. Take one of the adhesive sachets and carefully cut the flag tip off the notched end spout in line with the notch. 4. While holding the sachet vertical, slowly dribble the adhesive into the edge of the bolt hole as shown, ensuring that the adhesive flows into the joint between the seat rail and the zinc block. DO NOT pour the adhesive down the center of the hole. The object is to let the adhesive "wick" between the zinc block and the seat rail in order to bond the two pieces together. Important: If the bolt thread strips or the proper torque cannot be achieved, then the entire seat adjuster mechanism must be replaced. 5. Replace the previous bolt with a new M8 bolt (1) (included) and install using a "click torque wrench" preset to 9 N.m (79 lb in). 6. Remove the second M8 mounting bolt from the rail and discard. 7. Repeat steps 2 through 5 for the second bolt. 8. Repeat steps 2 through 6 for the opposite mounting rail. 9. Before installing the seat into the vehicle, verify that the seat will function correctly and does not make any unusual noises during forward and rearward travel motion. 10. Install the seat. Refer to the applicable Seats sub-section of SI. 11. While sitting in the seat, verify seat function and listen for any unusual noises. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 05-08-50-012A > Jul > 06 > Interior - Loose/Unwanted Seat Movement > Page 15627 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 05-08-50-012A > Jul > 06 > Interior - Loose/Unwanted Seat Movement Seat Track: All Technical Service Bulletins Interior - Loose/Unwanted Seat Movement Bulletin No.: 05-08-50-012A Date: July 24, 2006 TECHNICAL Subject: Unwanted/Loose Seat Movement (Apply Adhesive and Install New Bolts in Seat Mounting Rails) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac ESV 1999-2007 Chevrolet Silverado Pickup Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Pickup Models (Classic) 2000-2006 GMC Yukon, Yukon XL 2003-2006 HUMMER H2 with Power Driver Front Seat Power Adjuster (RPO AG1) and/or Passenger Seat Power Adjuster (RPO AG2) Supercede: This bulletin is being revised to add model years and additional Warranty Information. Please discard Corporate Bulletin Number 05-08-50-012 (Section 08 - Body and Accessories). Condition Some customers may comment on unwanted seat movement in the front power bucket seat (driver or passenger) during fast acceleration or hard braking. A metal to metal clicking noise is often heard at seat "stops." Cause The threads of the two zinc nut retainers (one on each side of the seat adjuster) may creep over time, causing a loss of self-rolling screw clamp load and ultimately causes relative rail and vehicle seat motion. Correction Apply adhesive and install new bolts in seat mounting rails using the following procedure. 1. Remove the front seat and invert onto a flat surface covered with a clean, non-scratch material (soft cloth or similar). Refer to the applicable Seats sub-section in SI. Adjust so that the seat mounting rails are at 45 degrees. 2. Remove the upper M8 mounting bolt from one rail and discard. Leave the other bolt intact as this will hold the track in place while working. Wipe the bolt hole area with a clean rag. Important: Only use the adhesive provided in the repair kit. Do not substitute with other adhesives. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 05-08-50-012A > Jul > 06 > Interior - Loose/Unwanted Seat Movement > Page 15633 3. Take one of the adhesive sachets and carefully cut the flag tip off the notched end spout in line with the notch. 4. While holding the sachet vertical, slowly dribble the adhesive into the edge of the bolt hole as shown, ensuring that the adhesive flows into the joint between the seat rail and the zinc block. DO NOT pour the adhesive down the center of the hole. The object is to let the adhesive "wick" between the zinc block and the seat rail in order to bond the two pieces together. Important: If the bolt thread strips or the proper torque cannot be achieved, then the entire seat adjuster mechanism must be replaced. 5. Replace the previous bolt with a new M8 bolt (1) (included) and install using a "click torque wrench" preset to 9 N.m (79 lb in). 6. Remove the second M8 mounting bolt from the rail and discard. 7. Repeat steps 2 through 5 for the second bolt. 8. Repeat steps 2 through 6 for the opposite mounting rail. 9. Before installing the seat into the vehicle, verify that the seat will function correctly and does not make any unusual noises during forward and rearward travel motion. 10. Install the seat. Refer to the applicable Seats sub-section of SI. 11. While sitting in the seat, verify seat function and listen for any unusual noises. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 05-08-50-012A > Jul > 06 > Interior - Loose/Unwanted Seat Movement > Page 15634 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Diagrams Door Latch Assembly (Key Cylinder Switch) - Driver C3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Description and Operation Pedal Positioning Switch: Description and Operation Brake Pedal Position Sensor Calibration Description and Operation Calibration Criteria The brake pedal position (BPP) sensor receives a low reference signal and a 5-volt reference signal from the electro-hydraulic power steering (EHPS). Whenever the brake pedal is applied, the brake pedal position sensor applies a variable voltage signal to the EHPS through the BPP sensor signal circuit. Brake pedal position sensor calibration must be performed after the brake pedal position sensor or EHPS system have been serviced. The calibration procedure will set brake pedal position sensor home value. This value is used by the EHPS to determine the brake pedal position and the brake pedal rate. These two outputs are provided to the hybrid control module (HCM) via GMLAN. Calibration Procedure 1. Install a scan tool. 2. Turn ON the ignition, with the engine OFF. 3. Important: Make sure the brake pedal is not depressed before sending BPP sensor calibration command. Navigate to the Special Functions screen on the scan tool and select BPP Sensor Calibration in order to perform the brake pedal position sensor calibration. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Description and Operation > Page 15642 Pedal Positioning Switch: Service and Repair Brake Pedal Position Sensor Replacement Removal Procedure 1. Important: Once the Brake Pedal Position Sensor bolt is removed for any reason, a new 4 mm bolt, with fresh LOCTITETM will need to be installed. Remove the brake pedal position sensor bolt (1). 2. Remove the brake pedal position sensor (2) from the mounting bracket. 3. Disconnect the brake pedal position sensor electrical connector (1). 4. Remove the brake pedal position sensor (2) from the vehicle Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Description and Operation > Page 15643 1. Connect the brake pedal position sensor (2) electrical connector (1). 2. Align the brake pedal position sensor (1) with the actuation arm (2) on the brake pedal and the brake pedal position sensor mounting bracket. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Description and Operation > Page 15644 3. Notice: Refer to Fastener Notice in Service Precautions. Install a new 4 mm bolt (1), with LOCTITETM , to the brake pedal position sensor. ^ Tighten the bolt to 9 Nm (80 inch lbs.). 4. Calibrate the brake pedal position sensor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Door Lock Switch - Driver (Base Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 15648 Door Lock Switch - Front Passenger (Base Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures Power Door Lock Switch: Procedures Switch Replacement - Door Lock and Side Window - Driver SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - DRIVER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 15651 6. Remove the door module from the switch panel bezel. INSTALLATION PROCEDURE 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten Tighten the screw to 2 N.m (18 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 15652 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Switch Replacement - Door Lock and Side Window - Passenger SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - PASSENGER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 15653 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. INSTALLATION PROCEDURE 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 15654 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 15655 Power Door Lock Switch: Removal and Replacement Switch Replacement - Door Lock and Side Window - Driver Switch Replacement - Door Lock and Side Window - Driver Removal Procedure 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 15656 Installation Procedure 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. See: Testing and Inspection/Programming and Relearning Switch Replacement - Door Lock and Side Window - Passenger Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 15657 Switch Replacement - Door Lock and Side Window - Passenger Removal Procedure 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 15658 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS). See: Testing and Inspection/Programming and Relearning Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 15663 Seat Lumbar Motor/Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 15664 Seat Front Vertical Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 15665 Seat Horizontal Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 15666 Power Seat Motor Position Sensor: Diagrams Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 15667 Seat Lumbar Motor/Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 15668 Seat Front Vertical Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 15669 Seat Horizontal Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 15670 Seat Rear Vertical Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Seat Bolster Motor/Position Sensor - Driver (With RPO Code AN3) > Page 15671 Seat Recliner Motor Position Sensor - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing Power Seat Switch: Customer Interest Interior - Power Seat Switch Knobs Loose/Missing Bulletin No.: 05-08-50-017 Date: December 14, 2005 TECHNICAL Subject: Power Front Seat (RPO AN3) Switch Knobs Loose or Missing (Replace Switch Knobs) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2006 GMC Sierra, Yukon, Yukon XL with Individual Front Seat Non-Bucket (RPO AN3) and Driver Front Seat Power Adjuster (AG1) and/or Passenger Front Seat Power Adjuster (AG2) Condition Some customers may comment that the power front seat adjuster switch knobs are loose and fall off or are missing. Correction Replace the front seat adjuster switch knob. These knobs were formerly available only as part of the power seat adjuster switch. DO NOT replace the switch if the knob only needs to be replaced. Parts Information Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing > Page 15680 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing Power Seat Switch: All Technical Service Bulletins Interior - Power Seat Switch Knobs Loose/Missing Bulletin No.: 05-08-50-017 Date: December 14, 2005 TECHNICAL Subject: Power Front Seat (RPO AN3) Switch Knobs Loose or Missing (Replace Switch Knobs) Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 2002-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2006 GMC Sierra, Yukon, Yukon XL with Individual Front Seat Non-Bucket (RPO AN3) and Driver Front Seat Power Adjuster (AG1) and/or Passenger Front Seat Power Adjuster (AG2) Condition Some customers may comment that the power front seat adjuster switch knobs are loose and fall off or are missing. Correction Replace the front seat adjuster switch knob. These knobs were formerly available only as part of the power seat adjuster switch. DO NOT replace the switch if the knob only needs to be replaced. Parts Information Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 05-08-50-017 > Dec > 05 > Interior - Power Seat Switch Knobs Loose/Missing > Page 15686 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 15687 Power Seat Switch: Locations Driver Seat (1 Of 2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 15688 Front Passenger Seat (1 Of 2) (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 15689 Power Seat Switch: Diagrams Seat Adjuster Switch - Driver (With RPO Code AN3) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 15690 Seat Adjuster Switch - Driver (With RPO Code AN3) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 15691 Seat Adjuster Switch - Driver (AG1) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 15692 Seat Adjuster Switch- Front Passenger (With RPO Code AN3) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 15693 Seat Adjuster Switch- Front Passenger (With RPO Code AN3) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 15694 Seat Bolster/Lumbar Switch - Driver (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 15695 Seat Bolster/Lumbar Switch - Front Passenger (With RPO Code AN3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures Power Seat Switch: Procedures Lumbar Switch Replacement LUMBAR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the power seat switch bezel containing the lumbar switch (1) from the seat. 2. Remove the lumbar switch screws from the power seat switch bezel. 3. Remove the lumbar switch. INSTALLATION PROCEDURE 1. Install the lumbar switch to the power seat switch bezel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the lumbar switch screws. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the power seat switch bezel (1) to the seat. Seat Switch Bezel Replacement SEAT SWITCH BEZEL REPLACEMENT REMOVAL PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 15698 1. Remove the screws retaining the power seat switch bezel. 2. Disconnect the electrical connectors. 3. Remove the lumbar support switch. 4. Remove the power seat adjuster switch assembly. INSTALLATION PROCEDURE 1. Install the power seat adjuster switch assembly to the seat switch bezel. 2. Install the lumbar support switch to the seat switch bezel. 3. Connect the electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws retaining the power seat switch bezel. Tighten Tighten the screws to 2 N.m (18 lb in). Seat Switch Replacement - Power SEAT SWITCH REPLACEMENT - POWER REMOVAL PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 15699 1. Remove the power seat switch bezel from the seat. 2. Remove the power seat switch to bezel screws. 3. Remove the power seat switch. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the power seat switch to bezel screws. Tighten Tighten the screws to 2 N.m (18 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 15700 2. Install the power seat switch bezel to the seat. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 15701 Power Seat Switch: Removal and Replacement Seat Switch Replacement - Power Removal Procedure 1. Remove the power seat switch bezel from the seat. 2. Remove the power seat switch to bezel screws. 3. Remove the power seat switch. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the power seat switch to bezel screws. Tighten the screws to 2 N.m (18 lb in). 2. Install the power seat switch bezel to the seat. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 04-08-50-007 > Mar > 04 > Interior - Front Heated Seat(s) Inoperative Seat Heater Switch: Customer Interest Interior - Front Heated Seat(s) Inoperative Bulletin No.: 04-08-50-007 Date: March 12, 2004 INFORMATION Subject: Service Information for Front Heated Seat Inoperative/Cold Models: 2003-2004 Cadillac Escalade/ESV/EXT 2003-2004 Chevrolet Avalanch/Silverado/Suburban/Tahoe 2003-2004 GMC Denali/Sierra/Yukon/Yukon XL 2003-2004 Hummer H2 The purpose of this bulletin is to provide the technician with the following service information: ^ Heated Seats Switch Operation ^ Heated Seats Switch Diagnostics ^ Heated Seats Switch Customer Information Switch Operation 1. The engine must be running for the heated seat feature to work. The heated seats will shut off automatically when the ignition is turned off. 2. Two buttons, located on the door, are used to control the heated seat. ^ Press the horizontal (RH) button to heat the entire seat, back and cushion. ^ Press the vertical (LH) button to heat ONLY the seat back. ^ The three light bars are an indicator of the level of heat selected for either the entire seat (horizontal button) or ONLY the seat back (vertical button). 3. To heat both the seat back and seat cushion at the same time, press the horizontal (RH) button with the heated seat symbol one time. ^ All 3 light bars will glow indicating the HIGH temperature setting. ^ The horizontal (RH) button does NOT have an ON/OFF indicator light. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 04-08-50-007 > Mar > 04 > Interior - Front Heated Seat(s) Inoperative > Page 15710 4. Press the button a second time, 2 light bars will glow indicating the MEDIUM temperature setting for the entire seat. 5. Press the button a third time, 1 light bar will glow indicating the LOW temperature setting for the entire seat. 6. Press the button a fourth time to turn the entire heated seat OFF. 7. To heat ONLY the seat back, press the vertical (LH) button one time. ^ An ON/OFF indicator light over the heated seat back symbol will glow to designate that ONLY the seat back is being heated. ^ All 3 light bars over the horizontal (RH) button will glow indicating the HIGH temperature setting for ONLY the seat back. 8. Press the button a second time, 2 light bars will glow indicating the MEDIUM temperature setting for ONLY the seat back. 9. Press the button a third time, 1 light bar will glow indicating the LOW temperature setting for ONLY the seat back. 10. Press the button a fourth time to turn the heated seat back OFF. Switch Diagnostics Important: In order to eliminate unnecessary part replacement and comeback repairs, it is essential that the appropriate diagnostic tables and aids found in the applicable manuals are followed. 1. Verify the condition prior to making any repairs. Refer to Seats and Seat Controls in the applicable Owners Manual or this bulletin for proper heated seat switch operation information. 2. If an improperly operating front heated seat condition exists, refer to the Diagnostic Information and Procedures in the Seats sub-section of the applicable Service Manual in order to diagnose the system accurately. 3. When measuring the resistance of the seat heater elements, ensure the values are within the updated range of 1.5-5.5 ohms. Refer to DTC B2425 or B2430-Clearing the DTC in the Diagnostic Information and Procedures in the Seats sub-section of the applicable Service Manual. Customer Information Some heated seat components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) for heat function not operating properly. Analyses of these parts show 'no out of specification condition' or No Trouble Found (NTF). 1. Provide customers with the knowledge that if bumped, either one of the heated seat switches can be activated/deactivated accidentally. 2. Ensure customers have a thorough understanding of how the heated seat switches function. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 04-08-50-007 > Mar > 04 > Interior - Front Heated Seat(s) Inoperative Seat Heater Switch: All Technical Service Bulletins Interior - Front Heated Seat(s) Inoperative Bulletin No.: 04-08-50-007 Date: March 12, 2004 INFORMATION Subject: Service Information for Front Heated Seat Inoperative/Cold Models: 2003-2004 Cadillac Escalade/ESV/EXT 2003-2004 Chevrolet Avalanch/Silverado/Suburban/Tahoe 2003-2004 GMC Denali/Sierra/Yukon/Yukon XL 2003-2004 Hummer H2 The purpose of this bulletin is to provide the technician with the following service information: ^ Heated Seats Switch Operation ^ Heated Seats Switch Diagnostics ^ Heated Seats Switch Customer Information Switch Operation 1. The engine must be running for the heated seat feature to work. The heated seats will shut off automatically when the ignition is turned off. 2. Two buttons, located on the door, are used to control the heated seat. ^ Press the horizontal (RH) button to heat the entire seat, back and cushion. ^ Press the vertical (LH) button to heat ONLY the seat back. ^ The three light bars are an indicator of the level of heat selected for either the entire seat (horizontal button) or ONLY the seat back (vertical button). 3. To heat both the seat back and seat cushion at the same time, press the horizontal (RH) button with the heated seat symbol one time. ^ All 3 light bars will glow indicating the HIGH temperature setting. ^ The horizontal (RH) button does NOT have an ON/OFF indicator light. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 04-08-50-007 > Mar > 04 > Interior - Front Heated Seat(s) Inoperative > Page 15716 4. Press the button a second time, 2 light bars will glow indicating the MEDIUM temperature setting for the entire seat. 5. Press the button a third time, 1 light bar will glow indicating the LOW temperature setting for the entire seat. 6. Press the button a fourth time to turn the entire heated seat OFF. 7. To heat ONLY the seat back, press the vertical (LH) button one time. ^ An ON/OFF indicator light over the heated seat back symbol will glow to designate that ONLY the seat back is being heated. ^ All 3 light bars over the horizontal (RH) button will glow indicating the HIGH temperature setting for ONLY the seat back. 8. Press the button a second time, 2 light bars will glow indicating the MEDIUM temperature setting for ONLY the seat back. 9. Press the button a third time, 1 light bar will glow indicating the LOW temperature setting for ONLY the seat back. 10. Press the button a fourth time to turn the heated seat back OFF. Switch Diagnostics Important: In order to eliminate unnecessary part replacement and comeback repairs, it is essential that the appropriate diagnostic tables and aids found in the applicable manuals are followed. 1. Verify the condition prior to making any repairs. Refer to Seats and Seat Controls in the applicable Owners Manual or this bulletin for proper heated seat switch operation information. 2. If an improperly operating front heated seat condition exists, refer to the Diagnostic Information and Procedures in the Seats sub-section of the applicable Service Manual in order to diagnose the system accurately. 3. When measuring the resistance of the seat heater elements, ensure the values are within the updated range of 1.5-5.5 ohms. Refer to DTC B2425 or B2430-Clearing the DTC in the Diagnostic Information and Procedures in the Seats sub-section of the applicable Service Manual. Customer Information Some heated seat components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) for heat function not operating properly. Analyses of these parts show 'no out of specification condition' or No Trouble Found (NTF). 1. Provide customers with the knowledge that if bumped, either one of the heated seat switches can be activated/deactivated accidentally. 2. Ensure customers have a thorough understanding of how the heated seat switches function. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Page 15717 Seat Heater Switch: Locations Driver Door Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Page 15718 Front Passenger Door Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Page 15719 Seat Heater Switch: Diagrams Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Page 15720 Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Page 15721 Front Passenger Door Module (FPDM) - C5 (Heated Seat Switch) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Page 15722 Heated Seat Switch - Front Passenger (FPDM C5) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Page 15723 Memory/Heated Seat Switch - Driver (DDM C5) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Page 15724 Memory/Heated Seat Switch - Driver (DDM C5) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch Replacement - Front Seat Heater Switch: Service and Repair Heated Seat Switch Replacement - Front HEATED SEAT SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connector. 3. Release the retaining clips for the front seat heater switch assembly in order to remove the switch. 4. Remove the front seat heater switch assembly. INSTALLATION PROCEDURE 1. Install the front seat heater switch assembly to the front trim panel by pressing the switch into place until the switch is completely seated. 2. Connect the electrical connector to the front seat heater switch assembly. 3. Install the front trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch Replacement - Front > Page 15727 Seat Heater Switch: Service and Repair Heated Seat Switch Replacement - Rear HEATED SEAT SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the center console end panel. 2. Disconnect the electrical connector. 3. Remove the seat heater switch retaining screws. 4. Remove the switch from the vehicle. INSTALLATION PROCEDURE 1. Install the switch to the console panel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screw. Tighten Tighten the screws to 1.6 N.m (14 lb in). 3. Connect the electrical connector. 4. Install the center console end panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations Driver Door Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 15731 Seat Memory Switch: Diagrams Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 15732 Driver Door Module (DDM) - C5 (Memory/Heated Seat Switch) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 15733 Memory/Heated Seat Switch - Driver (DDM C5) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 15734 Memory/Heated Seat Switch - Driver (DDM C5) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 15735 Seat Memory Switch: Service and Repair MEMORY SEAT SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connector. 3. Release the front seat memory switch assembly retaining clips in order to remove the switch. 4. Remove the front seat memory switch assembly. INSTALLATION PROCEDURE 1. Install the front seat memory switch assembly to the front trim panel by pressing into place until fully seated. 2. Connect the electrical connector to the front seat memory switch assembly. 3. Install the front trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Mud Flap > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up Mud Flap: Customer Interest Brakes/Wheels - Excessive Debris Build Up Bulletin No.: 04-05-23-005 Date: June 22, 2004 INFORMATION Subject: Availability of Rear Wheel Mud Flaps to Reduce Debris Build-up on Rear Brake Calipers and/or Rear Wheels Models: 1999-2004 Chevrolet Silverado Pickup Models 1999-2004 GMC Sierra Pickup Models This bulletin is to inform dealers of the release of rear wheel mud flaps. The above models that are exposed to extensive off-paved roads may benefit from the mud flaps. The mud flaps have been developed to minimize the amount of stones and/or mud that can impact and collect on the rear caliper and/or wheel rim. Please advise customers that the installation of these mud flaps and following the recommended off-road driving information provided in their Owner's Manual should greatly reduce the possibility of accelerated rear brake component wear and/or rim damage. Install the mud flap forward of each rear wheel using the following procedure. Important: Always work from outboard to inboard, drilling one hole at a time and securing with a fastener. Follow the sequence of the procedure. This will prevent distortion of the mud flap. 1. Raise the vehicle. Support the vehicle. 2. Locate the pickup box side panel rear brace. 3. Remove the existing outboard upper fastener on the brace. 4. Install the mud flap through the "V" of the brace. Install the previously removed fastener in the hole (2) of the mud flap to the brace. Do not tighten the fastener at this time. 5. Using the mud flap as a template, locate and mark the location of the hole (1) in the pickup box wheel house. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Mud Flap > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up > Page 15745 Important: After drilling the holes, apply the appropriate anti-corrosion primer. Refer to the GM Refinish Material Booklet # 4901 M-D (English) or # 4901-D-F (French) for additional information. 6. Center punch the marked location and drill a 6.35 mm (1/4 in) hole. Install the plastic retainer in the hole (1) of the mud flap. 7. Tighten fastener at the hole (2) location of the mud flap. Tighten Tighten the fastener to 25 N.m (18 lb ft). 8. For vehicles with short box, use the following procedure: 8.1. Push the mud flap to make contact with the rear side of the underbody cross sill and mark the location of the hole (3) of the mud flap. 8.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 8.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 8.4. Repeat the above steps for hole locations 4 and 6. 9. For vehicles with long box, use the following procedure: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Mud Flap > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up > Page 15746 9.1. Push the mud flap to make contact with the front side of the underbody cross sill and mark location of the hole (5) of the mud flap. 9.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 9.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 9.4. Repeat the above steps for hole location 6. 10. Repeat the above steps for the opposite side. Parts Information Parts are expected to be available from GMSPO on June 30, 2004. Warranty Information Please advise the customer that the mud flaps can be purchased as an accessory. Installation and/or cost of the mud flaps will not be covered under the vehicle's warranty. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Mud Flap > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up Mud Flap: All Technical Service Bulletins Brakes/Wheels - Excessive Debris Build Up Bulletin No.: 04-05-23-005 Date: June 22, 2004 INFORMATION Subject: Availability of Rear Wheel Mud Flaps to Reduce Debris Build-up on Rear Brake Calipers and/or Rear Wheels Models: 1999-2004 Chevrolet Silverado Pickup Models 1999-2004 GMC Sierra Pickup Models This bulletin is to inform dealers of the release of rear wheel mud flaps. The above models that are exposed to extensive off-paved roads may benefit from the mud flaps. The mud flaps have been developed to minimize the amount of stones and/or mud that can impact and collect on the rear caliper and/or wheel rim. Please advise customers that the installation of these mud flaps and following the recommended off-road driving information provided in their Owner's Manual should greatly reduce the possibility of accelerated rear brake component wear and/or rim damage. Install the mud flap forward of each rear wheel using the following procedure. Important: Always work from outboard to inboard, drilling one hole at a time and securing with a fastener. Follow the sequence of the procedure. This will prevent distortion of the mud flap. 1. Raise the vehicle. Support the vehicle. 2. Locate the pickup box side panel rear brace. 3. Remove the existing outboard upper fastener on the brace. 4. Install the mud flap through the "V" of the brace. Install the previously removed fastener in the hole (2) of the mud flap to the brace. Do not tighten the fastener at this time. 5. Using the mud flap as a template, locate and mark the location of the hole (1) in the pickup box wheel house. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Mud Flap > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up > Page 15752 Important: After drilling the holes, apply the appropriate anti-corrosion primer. Refer to the GM Refinish Material Booklet # 4901 M-D (English) or # 4901-D-F (French) for additional information. 6. Center punch the marked location and drill a 6.35 mm (1/4 in) hole. Install the plastic retainer in the hole (1) of the mud flap. 7. Tighten fastener at the hole (2) location of the mud flap. Tighten Tighten the fastener to 25 N.m (18 lb ft). 8. For vehicles with short box, use the following procedure: 8.1. Push the mud flap to make contact with the rear side of the underbody cross sill and mark the location of the hole (3) of the mud flap. 8.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 8.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 8.4. Repeat the above steps for hole locations 4 and 6. 9. For vehicles with long box, use the following procedure: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Mud Flap > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-05-23-005 > Jun > 04 > Brakes/Wheels - Excessive Debris Build Up > Page 15753 9.1. Push the mud flap to make contact with the front side of the underbody cross sill and mark location of the hole (5) of the mud flap. 9.2. Center punch the marked location and drill a 5.159 mm (13/64 in) hole. 9.3. Install the screw. Tighten Tighten the screw to 4 N.m (35 lb in). 9.4. Repeat the above steps for hole location 6. 10. Repeat the above steps for the opposite side. Parts Information Parts are expected to be available from GMSPO on June 30, 2004. Warranty Information Please advise the customer that the mud flaps can be purchased as an accessory. Installation and/or cost of the mud flaps will not be covered under the vehicle's warranty. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Mud Flap > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mud Flap: > 03-01-38-015A > Oct > 08 > A/C - Blower Motor Runs After Vehicle Is Shut OFF Blower Motor Relay: All Technical Service Bulletins A/C - Blower Motor Runs After Vehicle Is Shut OFF TECHNICAL Bulletin No.: 03-01-38-015A Date: October 27, 2008 Subject: HVAC Blower Motor May Run Continuously After Vehicle is Turned Off (Replace Blower Resistor Relay) Models: 2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2004 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon XL with Manual Control HVAC (RPO CJ3) Built Prior to August, 2003 Supercede: This bulletin is being revised to update the parts information. Please discard Corporate Bulletin Number 03-01-38-015 (Section 01 - HVAC). Condition Some customers may comment on the HVAC blower motor running after the vehicle has been turned off. The blower may run for just a few minutes or continuously until the battery is discharged. Cause A new style HVAC blower relay/resistor may stick in the "on" position. When the HVAC fan blower relay has been energized, the contacts may "micro-weld" together. After this occurrence, the HVAC blower may not respond to the HVAC controller commands. Correction Replace the HVAC blower resistor/relay with the type used previous to the 2004 model year. The appropriate part numbers are listed in the table below. For specific repair procedures, refer to the 2004 Service Information (SI) under Blower Motor Resistor Assembly Replacement (SI Document ID # 526350 (C/K) or # 729996 (S/T). Parts Information Warranty Information Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Service and Repair Tailgate Hinge: Service and Repair Hinge Replacement - Endgate Removal Procedure 1. Remove the endgate. 2. Remove the endgate hinge bolts. 3. Remove the hinge. 4. Remove the body side hinge bolts. 5. Remove the hinge from the vehicle. Installation Procedure 1. Install the body side hinge to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the body side hinge bolts. Tighten the bolts to 25 N.m (18 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Service and Repair > Page 15768 3. Install the endgate hinge to the vehicle. 4. Install the endgate hinge bolts. Tighten the bolts to 25 N.m (18 lb ft). 5. Install the endgate. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Technical Service Bulletins > Body - Revised Tailgate Latch Bezel Replacement Tailgate Latch: Technical Service Bulletins Body - Revised Tailgate Latch Bezel Replacement Bulletin No.: 05-08-66-005 Date: July 21, 2005 SERVICE MANUAL UPDATE Subject: SMU - Addition of Pickup Box End Gate Latch Handle Bezel Procedure Models: 2002-2005 Cadillac Escalade EXT 1999-2005 Chevrolet Silverado Pickup Models 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra Pickup Models This bulletin is being issued to add the Pickup Box End Gate Latch Handle Bezel procedure to the Body Rear End sub-section of the Service Manual. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Technical Service Bulletins > Body - Revised Tailgate Latch Bezel Replacement > Page 15773 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Technical Service Bulletins > Body - Revised Tailgate Latch Bezel Replacement > Page 15774 This information has been added within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Technical Service Bulletins > Page 15775 Tailgate Latch: Service and Repair Latch Replacement - Endgate Removal Procedure 1. Lower the endgate. 2. Loosen the handle bolts. 3. Raise the endgate. 4. Remove the handle bezel by prying gently on the upper retainer tabs. 5. Disengage the linkage rods (1). 6. Lower and support the endgate. 7. Remove the cables from the side panel cable retainer bolts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Technical Service Bulletins > Page 15776 8. Remove the bolt holding the latch assembly. 9. Disengage the linkage rod from the latch assembly. 10. Remove the latch assembly from the endgate. Installation Procedure 1. Engage the linkage rod to the latch assembly. 2. Install the latch assembly to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the latch assembly bolts. Tighten the bolts to 25 N.m (18 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Technical Service Bulletins > Page 15777 4. Connect the cables on each side of the endgate to the side panel cable retainer bolts. 5. Engage the linkage rods (1). 6. Raise the endgate. 7. Install the endgate handle bezel. Pressing into place until fully seated. 8. Tighten the handle bolts. Tighten the bolts to 25 N.m (18 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > End Gate Latch Handle Bezel Tailgate Release Handle: Service and Repair End Gate Latch Handle Bezel Removal and Installation 1. Release the adhesive blocks after the upper retaining tabs are released. 2. Install the latch handle bezel with the end gate in the closed position. 3. Clean the sheet metal at the right and left sides of the bezel opening with an alcohol wipe prior to the bezel installation. 4. Peel the protective tape liner from the foam block on both sides. 5. Seat the bezel at the bottom of the opening in the end gate. 6. Roll the bezel forward seating and securing the upper integral locking tabs. 7. Apply palm pressure to both outer edges of the bezel in order to wet out the adhesive foam blocks. 8. Integral Locking Tabs (Upper). ^ ENTRY Tip, gently pry downward with a small flat-bladed tool at the two locations in order to release the upper retaining tabs. 9. Integral Retention Tabs (Lower). 10. End Gate Latch Handle Bezel. ^ ENTRY Tip, once in position, gently wet out the adhesive foam blocks to the end gate panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > End Gate Latch Handle Bezel > Page 15782 Tailgate Release Handle: Service and Repair Handle Replacement - Endgate Handle Replacement - Endgate Removal Procedure 1. Loosen the handle bolts. 2. Remove the handle bezel by prying gently on the upper retainer tabs. 3. Disengage the linkage rods (1). 4. Remove the handle bolts. 5. Remove the handle assembly from the endgate. Installation Procedure 1. Position the handle assembly on the endgate. 2. Install the handle bolts loosely. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > End Gate Latch Handle Bezel > Page 15783 3. Engage the linkage rods (1). 4. Install the handle bezel. Notice: Refer to Fastener Notice in Service Precautions. 5. Tighten the handle bolts. Tighten the bolts to 25 N.m (18 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > End Gate Latch Handle Bezel > Page 15784 Tailgate Release Handle: Service and Repair Handle Rod Retainer Replacement - Endgate Handle Rod Retainer Replacement - Endgate Removal Procedure 1. Open the endgate. 2. Remove the fasteners (1) retaining the endgate handle bezel. 3. Remove the endgate handle bezel 4. Release the endgate latch rod from the handle rod retainer. 5. Release the retaining clip (2) and remove the handle rod retainer from the handle. Installation Procedure 1. Install the handle rod retainer to the handle, ensuring the retaining clip (2) is fully seated. 2. Attach the endgate latch rod to the handle rod retainer. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > End Gate Latch Handle Bezel > Page 15785 3. Install the endgate handle bezel. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the fasteners (1) retaining the endgate handle bezel. Tighten the fasteners to 2.5 N.m (22 lb in). 5. Close the endgate. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall - Tailgate Support Cable Inspection/Replacement Technical Service Bulletin # 04007B Date: 051121 Recall - Tailgate Support Cable Inspection/Replacement Product Safety - Tailgate Support Cable # 04007B - (Nov 21, 2005) Models: 2002-2004 Cadillac Escalade EXT 2000 Chevrolet CK 2000-2004 Chevrolet Silverado 2002-2004 Chevrolet Avalanche 2003-2004 Chevrolet Kodiak 2000-2004 GMC Sierra 2003-2004 GMC TopKick THIS BULLETIN IS BEING REVIED TO INCLUDE SOME 2003 AND 2004 MODEL YEAR MEDIUM DUTY VEHICLES THAT WERE MODIFIED TO INCLUDE A TAILGATE. PLEASE DISCARD ALL COPIES OF BULLETIN 04007A, ISSUED OCTOBER 2004. Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2000 model year Chevrolet CK, 2000-2004 model year Chevrolet Silverado and GMC Sierra trucks, and 2002-2004 model year Cadillac Escalade EXT and Chevrolet Avalanche trucks, and 2003-2004 Chevrolet Kodiak and GMC TopKick trucks. On some of these vehicles, the galvanized steel tailgate support cables that retain the tailgate in the full open (horizontal) position may corrode, weaken, and eventually fracture. If one cable fractures, the remaining cable may retain the tailgate in a horizontal position. However, if the remaining cable is sufficiently weakened by corrosion, it could fracture within moments of the first cable fracturing, especially if there is a load on the tailgate. If both cables fracture, the tailgate would suddenly drop and strike the top surface of the rear bumper. Anyone sitting or standing on the tailgate when both cable fracture could be injured by falling from the tailgate. On vehicles that have had the bumper removed, the tailgate may drop even lower. Additionally, if there is cargo on the tailgate, the cargo may become unstable and fall if the support cables fracture. Correction Dealers are to replace the galvanized support cables with stainless steel support cables. In addition, dealers are to inspect the tailgate hinge and replace it, if necessary. Vehicles Involved Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall - Tailgate Support Cable Inspection/Replacement > Page 15794 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall - Tailgate Support Cable Inspection/Replacement > Page 15795 Involved are certain 2000 Chevrolet CK, 2000-2004 model year Chevrolet Silverado and GMC Sierra trucks, and 2002-2004 model year Cadillac Escalade EXT and Chevrolet Avalanche trucks, and 2003-2004 Chevrolet Kodiak and GMC TopKick trucks built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall - Tailgate Support Cable Inspection/Replacement > Page 15796 report with the recall bulletin. For IPC For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall - Tailgate Support Cable Inspection/Replacement > Page 15797 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall - Tailgate Support Cable Inspection/Replacement > Page 15798 A General Motors Product Recall Customer Reimbursement Procedure Form is shown. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12 for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to correct the condition addressed in this bulletin are to be submitted by January 31, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall - Tailgate Support Cable Inspection/Replacement > Page 15799 and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall - Tailgate Support Cable Inspection/Replacement > Page 15800 Submit a Product Recall claim with the information shown. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin)) Customer Notification -- For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall - Tailgate Support Cable Inspection/Replacement > Page 15801 to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT PROGRAM CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is: ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Please follow the instructions on the claim Form previously show to file e a claim for reimbursement. If you have questions about this reimbursement procedure, please contact the toll free telephone number provided at the bottom of the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number shown. The Customer Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern standard time Monday through Friday. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall - Tailgate Support Cable Inspection/Replacement > Page 15802 Service Procedure Classic Silverado and Sierra (GMT400) The following procedure provides instructions for inspecting, and if necessary, replacing the rear endgate (tailgate) support cables and inspecting the right side tailgate hinge for damage, and replacing if recessary. Notice: It is recommended that a support be placed under the open tailgate in the next step to prevent the tailgate from being damaged in the event that it drops when disconnecting, inspecting, and replacing the support cables. Hinge Inspection - Classic CK and Sierra 1. Release (unhook) the RIGHT side tailgate support cable from the pickup box. 2. With the tailgate (1) completely open as shown in the upper part of the illustration, pull the RIGHT SIDE of the tailgate rearward as shown in the lower illustration. Do not pull on the left side of the tailgate. - If the tailgate hinge (2) will NOT disengage from the pickup box on the right side, no repair is needed to the hinge. Proceed to the section titled, "Support Cable Replacement" and replace both support cables. - If the tailgate hinge (3) WILL disengage from the pickup box on the right side, proceed to the next step. 3. With the right side of the tailgate disengaged from the pickup box, inspect the hinge on the right side of the tailgate for damage. The illustration above shows an undamaged hinge (1) and a damaged or bent hinge (2). - If the hinge is NOT damaged, no repair is needed to the hinge. Proceed to the section titled, "Support Cable Replacement" and replace both support cables. - If the hinge IS damaged or bent, the hinge needs to be replaced. Proceed to the section titled, "Hinge Replacement" before proceeding with the replacement of the support cables. Hinge Replacement - Classic CK and Sierra Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall - Tailgate Support Cable Inspection/Replacement > Page 15803 The following procedure should only be performed if the right side of the tailgate could be disengaged for the pickup truck and the hinge was damaged or bent. 1. Release (unhook) the left side tailgate support cable from the pickup box. 2. Remove the tailgate from the vehicle. 3. Remove the bolt (1) attaching the right side hinge (2) to the side of the tailgate. 4. Locate and drill out the large weld (2) attaching the hinge (1) to the backside of the tailgate bracket (3). Remove the hinge. Important: Because the new hinge must be welded to the bracket on the tailgate in the next steps, do not paint the hinge until after installation. After welding is complete, the new hinge must be primed and painted in the body color. 5. Install a new hinge to the tailgate and install the bolt. Tighten Tighten the bolt to 27 Nm (20 lb-ft). 6. Weld the backside of the new hinge to the original bracket on the tailgate. 7. Tape off the area around the hinge and prime and paint the hinge as required. 8. Reinstall the tailgate on the vehicle and proceed to the section titled, "Support Cable Replacement". Support Cable Replacement - Classic CK and Sierra The following procedure provides instruction for replacing the rear endgate (tailgate) support cables. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall - Tailgate Support Cable Inspection/Replacement > Page 15804 1. Open the rear tailgate and support it as necessary. 2. Release (unhook) the right side tailgate support cable from the pickup box. Important: If the support cable (2) has NOT been replaced previously, there will be a toothed nut or plastic nut (1) located between the latch (4) and the tailgate that MAY prevent the bolt (3) from being removed in the next step. The nut is an assembly aid used in the assembly plant. Do not reinstall or replace the toothed or plastic nut when installing the new support cable. 3. Loosen the bolt (3) that attaches the opposite end of the support cable to the latch assembly (2). - If the toothed or plastic nut IS present, you will only be able to loosen the bolt partially from the latch. If this condition is encountered, proceed to the next step. - If the toothed or plastic nut is NOT present, proceed to Step 8. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall - Tailgate Support Cable Inspection/Replacement > Page 15805 4. Important: DO NOT loosen the other bolt completely in the next step. Leave two or three threads of the bolt engaged in the tailgate. Removing this bolt completely may allow the linkage inside the tailgate to separate from the latch. 5. If the toothed or plastic nut is present, loosen the other two bolts (1) attaching the latch (2) to the tailgate. DO NOT remove these bolts. 6. Finish loosening the bolt that attaches the support cable. The bolt will NOT be removable even though the threads are completely out. 7. Place an interior trim removal type tool (2) between the support cable end (3) and the latch (1), and pry the two apart. As the two spread apart, the toothed or plastic nut on the other side of the latch will begin to move towards the end of the bolt. 8. Once the toothed or plastic nut has moved away from the backside of the latch, use long nose pliers to grasp and twist it off of the bolt. Discard the toothed nut. 9. Remove the bolt and support cable. Important: Do not reinstall the toothed or plastic nut when installing the new support cable. Also, the support cables used on these vehicles are interchangeable from side to side, and no washers are to be installed like those used on the new style trucks (GMT800). 10. Install the new support cable to the latch and reinstall the original bolt. Tighten Tighten the bolt to 30 Nm (22 lb-ft). 11. If the other bolts were loosened earlier, Tighten Tighten the other loose bolts to 30 Nm (22 lb-ft). 12. Attach the opposite end of the support cable to the pickup box. 13. Repeat this procedure on the other support cable. Important: Depending on the condition of the tailgate and related parts, one of the two new support cables (either left or right) may NOT be tight (taut) when the tailgate is fully open. This condition may be caused by several factors including a damaged hinge, pickup box, or the tailgate itself may be slightly bent due to overloading at some previous time. Replacing either or both support cables a second time will NOT correct this condition. Replacement of any additional parts to correct this condition will NOT be covered under this recall. 14. Remove the tailgate support, close, open and re-close the tailgate. Verify that the support cables fold properly. Escalade EXT, Avalanche, New Style Silverado and Sierra (GMT800), Kodiak, TopKick The following procedures provides instructions for inspecting, and if necessary, replacing the rear endgate (tailgate) support cables and inspecting the right side tailgate hinge for damage, and replacing if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall - Tailgate Support Cable Inspection/Replacement > Page 15806 Notice: It is recommended that a support be placed under the open tailgate in the next step to prevent the tailgate from being damaged in the event that it drops when disconnecting, inspecting, and replacing the support cables. Support Cable Inspection - Escalade EXT, Avalanche, New Style Silverado and Sierra, Kodiak, TopKick 1. Open the rear tailgate and support it as necessary. 2. Release (unhook) the right side tailgate support cable from the pickup box. Important: In the above illustration, the clear sealant (1) is shown as black in color. This was done for illustration purposes only. If sealant is present on the support cables it will be clear or hazy (cloudy) in appearance. 3. Inspect the end (eyelet) of the support cable that attaches to the tailgate for sealant covering the end of the cable strands. - If there IS a clear type sealant (1) over the end of the cable strands, the support cable needs to be replaced. Reconnect the support cable to the pickup box and perform this same inspection on the left support cable. After inspecting both cables, proceed to the section titled "Hinge Inspection". - If there IS NOT a clear type sealant (2) over the end of the cable strands, that support cable does NOT need to be replaced. Reconnect the support cable to the pickup box and perform this same inspection on the left support cable. After inspecting both cables, proceed to the section titled "Hinge Inspection". Hinge Inspection - Escalade EXT, Avalanche, New Style Silverado and Sierra, Kodiak, TopKick 1. Release (unhook) the RIGHT side tailgate support cable from the pickup box aga1n. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall - Tailgate Support Cable Inspection/Replacement > Page 15807 2. With the tailgate (1) completely open as shown in the upper part of the illustration, pull the RIGHT SIDE of the tailgate rearward as shown in the lower illustration. Do not pull on the left side of the tailgate. - If the tailgate hinge (2) will NOT disengage from the pickup box on the right side, no repair is needed to the hinge. Proceed to the section titled "Support Cable Replacement" and replace any support cable that HAD sealant in the earlier inspection. If neither of the support cables requires replacement, no further action is required. - If the tailgate hinge (3) will disengage from the pickup box on the right side, proceed to the next step. 3. With the right side of the tailgate disengaged from the pickup box, inspect the hinge on the right side of the tailgate for damage. The illustration above shows an undamaged hinge (1) and a damaged or bent hinge (2). - If the hinge is NOT damaged, no repair is needed to the hinge. Proceed to the section titled, "Support Cable Replacement" and replace any support cables that HAD sealant in the earlier inspection. If neither of the support cables require replacement, no further action is required. - If the hinge IS damaged or bent, the hinge needs to be replaced. Proceed to the section titled, "Hinge Replacement". Hinge Replacement - Escalade EXT, Avalanche, New Style Silverado and Sierra, Kodiak, TopKick The following procedure should only be performed if the right side of the tailgate could be disengaged from the pickup box. 1. Release (unhook) the left side tailgate support cable from the pickup box. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall - Tailgate Support Cable Inspection/Replacement > Page 15808 2. Remove the tailgate from the vehicle. 3. Remove the two bolts attaching the right side hinge to the tailgate. Important: On Chevrolet Silverado and GMC Sierra models, the NEW hinge being installed must be primed and painted in the body color prior to installation. New hinges for the Chevrolet Avalanche and Cadillac Escalade EXT come pre-painted in a glossy back primer, these hinges must still be painted black. 4. Install a NEW hinge to the tailgate and install the two bolts. Tighten Tighten the bolts to 25 Nm (18 lb-ft). 5. Reinstall the tailgate on the vehicle. If one or both tailgate support cables require replacement, proceed to the section titled "Support Cable Replacement". If neither support cables require replacement, no further action is required. Support Cable Replacement - Escalade EXT, Avalanche, New Style Silverado and Sierra, Kodiak, TopKick The following procedure should only be performed if sealant was found in one or both support cables in the earlier inspection. Important: If the support cable (2) has NOT been replaced previously, there will be a toothed nut (1) located between the latch (4) and the tailgate that will prevent the bolt (3) from being removed in the next step. The nut is an assembly aid used in the assembly plant. The nut does NOT need to be reinstalled or replaced when installing a new support cable in this recall. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall - Tailgate Support Cable Inspection/Replacement > Page 15809 1. Loosen the bolt (1) that attaches the opposite end of the support cable to the latch assembly (2). - If the toothed nut is present, you will only be able to loosen the bolt partily from the latch. If this condition is encountered, proceed to the next step. - If the toothed nut is not present, proceed to Step 6. 3. Important: DO NOT loosen the other bolt completely in the next step. Leave two or three threads of the bolt engaged in the tailgate. Removing this bolt completely may allow the linkage inside the tailgate to separate from the latch. 4. If the toothed nut is present, loosen the other bolt (3) attaching the latch to the tailgate. DO NOT remove this bolt. 5. Finish loosening the bolt that attaches the support cable. The bolt will NOT be removable even though the threads are completely out. 6. Place an interior trim removal type tool (2), or equivalent, between the support cable end (3) and the latch (1), and pry the two apart. As the two spread apart, the toothed nut on the other side of the latch will begin to move towards the end of the bolt. 7. Once the toothed nut has moved away from the backside of the latch, use long nose pliers to grasp and twist it off of the bolt. Discard the toothed nut. 8. Remove the bolt and support cable. Notice: Due to manufacturing variation in the thickness of the latch, support cable end, and the shoulder on the bolt, a spacer (flat washer) must be used when installing the new cable. The washer will act as an extension to the shoulder on the bolt, and the outside diameter of the washer will allow it to fit inside of the opening in the cable end. This will allow the cable end to rotate freely on the bolt/latch when the tailgate is closed and prevent the support cable from getting pinched between the tailgate and the pickup box. The washer does part number listed in this bulletin MUST BE used when installing the new support cables. Its dimensions are critical for correct cable positioning when closing the tailgate and it has the corrosion protection specified by GM. DO NOT use any other washer in place of the one listed in this recall. Important: The washer does NOT replace the toothed nut removed earlier and is NOT to be installed between the latch and the tailgate. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall - Tailgate Support Cable Inspection/Replacement > Page 15810 Notice: When installing the new support cable, make sure that the left side (LS) is installed on the left (driver's) side of the vehicle, and the right side (RS) is installed on the right (passenger) side. The support cables are marked with an LS or RS on the end of the cable that attaches to the tailgate. Installing a support cable on the incorrect side of the vehicle may result in the cable getting damaged when the tailgate is closed. 9. Install one new flat washer on the bolt followed by a new support cable. The end of the support cable should go over the washer and onto the shoulder of the bolt. 10. Install the bolt, flat washer, and cable assembly into the latch and tailgate. Tighten Tighten the bolt to 25 Nm (18 lb-ft). 11. If the other bolt was loosened earlier, Tighten Tighten the bolt to 25 Nm (18 lb-ft). 12. Verify that the support cable end rotates freely on the bolt. 13. Attach the opposite end of the support cable to the pickup box. 14. Repeat the procedure on the other support cable~ Important: Depending on the condition of the tailgate and related parts, one of the two new support cables (either left or right) may NOT be tight (taut) when the tailgate is fully open. This condition may be caused by several factors including a damaged hinge, pickup box, or the tailgate itself may be slightly bent due to overloading at some previous time. Replacing either or both support cables a second time will NOT correct this condition. Replacement of any additional parts to correct this condition will NOT be covered under this recall. 15. Remove the tailgate support, close, open and re-close the tailgate. Verify that the support cables fold properly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall - Tailgate Support Cable Inspection/Replacement > Page 15811 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall - Tailgate Support Cable Inspection/Replacement > Page 15812 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall - Tailgate Support Cable Inspection/Replacement > Page 15813 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall Tailgate Support Cable Inspection/Replacement Technical Service Bulletin # 04007B Date: 051121 Recall - Tailgate Support Cable Inspection/Replacement Product Safety - Tailgate Support Cable # 04007B - (Nov 21, 2005) Models: 2002-2004 Cadillac Escalade EXT 2000 Chevrolet CK 2000-2004 Chevrolet Silverado 2002-2004 Chevrolet Avalanche 2003-2004 Chevrolet Kodiak 2000-2004 GMC Sierra 2003-2004 GMC TopKick THIS BULLETIN IS BEING REVIED TO INCLUDE SOME 2003 AND 2004 MODEL YEAR MEDIUM DUTY VEHICLES THAT WERE MODIFIED TO INCLUDE A TAILGATE. PLEASE DISCARD ALL COPIES OF BULLETIN 04007A, ISSUED OCTOBER 2004. Condition General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2000 model year Chevrolet CK, 2000-2004 model year Chevrolet Silverado and GMC Sierra trucks, and 2002-2004 model year Cadillac Escalade EXT and Chevrolet Avalanche trucks, and 2003-2004 Chevrolet Kodiak and GMC TopKick trucks. On some of these vehicles, the galvanized steel tailgate support cables that retain the tailgate in the full open (horizontal) position may corrode, weaken, and eventually fracture. If one cable fractures, the remaining cable may retain the tailgate in a horizontal position. However, if the remaining cable is sufficiently weakened by corrosion, it could fracture within moments of the first cable fracturing, especially if there is a load on the tailgate. If both cables fracture, the tailgate would suddenly drop and strike the top surface of the rear bumper. Anyone sitting or standing on the tailgate when both cable fracture could be injured by falling from the tailgate. On vehicles that have had the bumper removed, the tailgate may drop even lower. Additionally, if there is cargo on the tailgate, the cargo may become unstable and fall if the support cables fracture. Correction Dealers are to replace the galvanized support cables with stainless steel support cables. In addition, dealers are to inspect the tailgate hinge and replace it, if necessary. Vehicles Involved Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall Tailgate Support Cable Inspection/Replacement > Page 15819 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall Tailgate Support Cable Inspection/Replacement > Page 15820 Involved are certain 2000 Chevrolet CK, 2000-2004 model year Chevrolet Silverado and GMC Sierra trucks, and 2002-2004 model year Cadillac Escalade EXT and Chevrolet Avalanche trucks, and 2003-2004 Chevrolet Kodiak and GMC TopKick trucks built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall Tailgate Support Cable Inspection/Replacement > Page 15821 report with the recall bulletin. For IPC For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall Tailgate Support Cable Inspection/Replacement > Page 15822 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall Tailgate Support Cable Inspection/Replacement > Page 15823 A General Motors Product Recall Customer Reimbursement Procedure Form is shown. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12 for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to correct the condition addressed in this bulletin are to be submitted by January 31, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall Tailgate Support Cable Inspection/Replacement > Page 15824 and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall Tailgate Support Cable Inspection/Replacement > Page 15825 Submit a Product Recall claim with the information shown. Customer Notification -- For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin)) Customer Notification -- For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall Tailgate Support Cable Inspection/Replacement > Page 15826 to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT PROGRAM CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is: ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Please follow the instructions on the claim Form previously show to file e a claim for reimbursement. If you have questions about this reimbursement procedure, please contact the toll free telephone number provided at the bottom of the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number shown. The Customer Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern standard time Monday through Friday. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall Tailgate Support Cable Inspection/Replacement > Page 15827 Service Procedure Classic Silverado and Sierra (GMT400) The following procedure provides instructions for inspecting, and if necessary, replacing the rear endgate (tailgate) support cables and inspecting the right side tailgate hinge for damage, and replacing if recessary. Notice: It is recommended that a support be placed under the open tailgate in the next step to prevent the tailgate from being damaged in the event that it drops when disconnecting, inspecting, and replacing the support cables. Hinge Inspection - Classic CK and Sierra 1. Release (unhook) the RIGHT side tailgate support cable from the pickup box. 2. With the tailgate (1) completely open as shown in the upper part of the illustration, pull the RIGHT SIDE of the tailgate rearward as shown in the lower illustration. Do not pull on the left side of the tailgate. - If the tailgate hinge (2) will NOT disengage from the pickup box on the right side, no repair is needed to the hinge. Proceed to the section titled, "Support Cable Replacement" and replace both support cables. - If the tailgate hinge (3) WILL disengage from the pickup box on the right side, proceed to the next step. 3. With the right side of the tailgate disengaged from the pickup box, inspect the hinge on the right side of the tailgate for damage. The illustration above shows an undamaged hinge (1) and a damaged or bent hinge (2). - If the hinge is NOT damaged, no repair is needed to the hinge. Proceed to the section titled, "Support Cable Replacement" and replace both support cables. - If the hinge IS damaged or bent, the hinge needs to be replaced. Proceed to the section titled, "Hinge Replacement" before proceeding with the replacement of the support cables. Hinge Replacement - Classic CK and Sierra Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall Tailgate Support Cable Inspection/Replacement > Page 15828 The following procedure should only be performed if the right side of the tailgate could be disengaged for the pickup truck and the hinge was damaged or bent. 1. Release (unhook) the left side tailgate support cable from the pickup box. 2. Remove the tailgate from the vehicle. 3. Remove the bolt (1) attaching the right side hinge (2) to the side of the tailgate. 4. Locate and drill out the large weld (2) attaching the hinge (1) to the backside of the tailgate bracket (3). Remove the hinge. Important: Because the new hinge must be welded to the bracket on the tailgate in the next steps, do not paint the hinge until after installation. After welding is complete, the new hinge must be primed and painted in the body color. 5. Install a new hinge to the tailgate and install the bolt. Tighten Tighten the bolt to 27 Nm (20 lb-ft). 6. Weld the backside of the new hinge to the original bracket on the tailgate. 7. Tape off the area around the hinge and prime and paint the hinge as required. 8. Reinstall the tailgate on the vehicle and proceed to the section titled, "Support Cable Replacement". Support Cable Replacement - Classic CK and Sierra The following procedure provides instruction for replacing the rear endgate (tailgate) support cables. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall Tailgate Support Cable Inspection/Replacement > Page 15829 1. Open the rear tailgate and support it as necessary. 2. Release (unhook) the right side tailgate support cable from the pickup box. Important: If the support cable (2) has NOT been replaced previously, there will be a toothed nut or plastic nut (1) located between the latch (4) and the tailgate that MAY prevent the bolt (3) from being removed in the next step. The nut is an assembly aid used in the assembly plant. Do not reinstall or replace the toothed or plastic nut when installing the new support cable. 3. Loosen the bolt (3) that attaches the opposite end of the support cable to the latch assembly (2). - If the toothed or plastic nut IS present, you will only be able to loosen the bolt partially from the latch. If this condition is encountered, proceed to the next step. - If the toothed or plastic nut is NOT present, proceed to Step 8. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall Tailgate Support Cable Inspection/Replacement > Page 15830 4. Important: DO NOT loosen the other bolt completely in the next step. Leave two or three threads of the bolt engaged in the tailgate. Removing this bolt completely may allow the linkage inside the tailgate to separate from the latch. 5. If the toothed or plastic nut is present, loosen the other two bolts (1) attaching the latch (2) to the tailgate. DO NOT remove these bolts. 6. Finish loosening the bolt that attaches the support cable. The bolt will NOT be removable even though the threads are completely out. 7. Place an interior trim removal type tool (2) between the support cable end (3) and the latch (1), and pry the two apart. As the two spread apart, the toothed or plastic nut on the other side of the latch will begin to move towards the end of the bolt. 8. Once the toothed or plastic nut has moved away from the backside of the latch, use long nose pliers to grasp and twist it off of the bolt. Discard the toothed nut. 9. Remove the bolt and support cable. Important: Do not reinstall the toothed or plastic nut when installing the new support cable. Also, the support cables used on these vehicles are interchangeable from side to side, and no washers are to be installed like those used on the new style trucks (GMT800). 10. Install the new support cable to the latch and reinstall the original bolt. Tighten Tighten the bolt to 30 Nm (22 lb-ft). 11. If the other bolts were loosened earlier, Tighten Tighten the other loose bolts to 30 Nm (22 lb-ft). 12. Attach the opposite end of the support cable to the pickup box. 13. Repeat this procedure on the other support cable. Important: Depending on the condition of the tailgate and related parts, one of the two new support cables (either left or right) may NOT be tight (taut) when the tailgate is fully open. This condition may be caused by several factors including a damaged hinge, pickup box, or the tailgate itself may be slightly bent due to overloading at some previous time. Replacing either or both support cables a second time will NOT correct this condition. Replacement of any additional parts to correct this condition will NOT be covered under this recall. 14. Remove the tailgate support, close, open and re-close the tailgate. Verify that the support cables fold properly. Escalade EXT, Avalanche, New Style Silverado and Sierra (GMT800), Kodiak, TopKick The following procedures provides instructions for inspecting, and if necessary, replacing the rear endgate (tailgate) support cables and inspecting the right side tailgate hinge for damage, and replacing if necessary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall Tailgate Support Cable Inspection/Replacement > Page 15831 Notice: It is recommended that a support be placed under the open tailgate in the next step to prevent the tailgate from being damaged in the event that it drops when disconnecting, inspecting, and replacing the support cables. Support Cable Inspection - Escalade EXT, Avalanche, New Style Silverado and Sierra, Kodiak, TopKick 1. Open the rear tailgate and support it as necessary. 2. Release (unhook) the right side tailgate support cable from the pickup box. Important: In the above illustration, the clear sealant (1) is shown as black in color. This was done for illustration purposes only. If sealant is present on the support cables it will be clear or hazy (cloudy) in appearance. 3. Inspect the end (eyelet) of the support cable that attaches to the tailgate for sealant covering the end of the cable strands. - If there IS a clear type sealant (1) over the end of the cable strands, the support cable needs to be replaced. Reconnect the support cable to the pickup box and perform this same inspection on the left support cable. After inspecting both cables, proceed to the section titled "Hinge Inspection". - If there IS NOT a clear type sealant (2) over the end of the cable strands, that support cable does NOT need to be replaced. Reconnect the support cable to the pickup box and perform this same inspection on the left support cable. After inspecting both cables, proceed to the section titled "Hinge Inspection". Hinge Inspection - Escalade EXT, Avalanche, New Style Silverado and Sierra, Kodiak, TopKick 1. Release (unhook) the RIGHT side tailgate support cable from the pickup box aga1n. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall Tailgate Support Cable Inspection/Replacement > Page 15832 2. With the tailgate (1) completely open as shown in the upper part of the illustration, pull the RIGHT SIDE of the tailgate rearward as shown in the lower illustration. Do not pull on the left side of the tailgate. - If the tailgate hinge (2) will NOT disengage from the pickup box on the right side, no repair is needed to the hinge. Proceed to the section titled "Support Cable Replacement" and replace any support cable that HAD sealant in the earlier inspection. If neither of the support cables requires replacement, no further action is required. - If the tailgate hinge (3) will disengage from the pickup box on the right side, proceed to the next step. 3. With the right side of the tailgate disengaged from the pickup box, inspect the hinge on the right side of the tailgate for damage. The illustration above shows an undamaged hinge (1) and a damaged or bent hinge (2). - If the hinge is NOT damaged, no repair is needed to the hinge. Proceed to the section titled, "Support Cable Replacement" and replace any support cables that HAD sealant in the earlier inspection. If neither of the support cables require replacement, no further action is required. - If the hinge IS damaged or bent, the hinge needs to be replaced. Proceed to the section titled, "Hinge Replacement". Hinge Replacement - Escalade EXT, Avalanche, New Style Silverado and Sierra, Kodiak, TopKick The following procedure should only be performed if the right side of the tailgate could be disengaged from the pickup box. 1. Release (unhook) the left side tailgate support cable from the pickup box. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall Tailgate Support Cable Inspection/Replacement > Page 15833 2. Remove the tailgate from the vehicle. 3. Remove the two bolts attaching the right side hinge to the tailgate. Important: On Chevrolet Silverado and GMC Sierra models, the NEW hinge being installed must be primed and painted in the body color prior to installation. New hinges for the Chevrolet Avalanche and Cadillac Escalade EXT come pre-painted in a glossy back primer, these hinges must still be painted black. 4. Install a NEW hinge to the tailgate and install the two bolts. Tighten Tighten the bolts to 25 Nm (18 lb-ft). 5. Reinstall the tailgate on the vehicle. If one or both tailgate support cables require replacement, proceed to the section titled "Support Cable Replacement". If neither support cables require replacement, no further action is required. Support Cable Replacement - Escalade EXT, Avalanche, New Style Silverado and Sierra, Kodiak, TopKick The following procedure should only be performed if sealant was found in one or both support cables in the earlier inspection. Important: If the support cable (2) has NOT been replaced previously, there will be a toothed nut (1) located between the latch (4) and the tailgate that will prevent the bolt (3) from being removed in the next step. The nut is an assembly aid used in the assembly plant. The nut does NOT need to be reinstalled or replaced when installing a new support cable in this recall. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall Tailgate Support Cable Inspection/Replacement > Page 15834 1. Loosen the bolt (1) that attaches the opposite end of the support cable to the latch assembly (2). - If the toothed nut is present, you will only be able to loosen the bolt partily from the latch. If this condition is encountered, proceed to the next step. - If the toothed nut is not present, proceed to Step 6. 3. Important: DO NOT loosen the other bolt completely in the next step. Leave two or three threads of the bolt engaged in the tailgate. Removing this bolt completely may allow the linkage inside the tailgate to separate from the latch. 4. If the toothed nut is present, loosen the other bolt (3) attaching the latch to the tailgate. DO NOT remove this bolt. 5. Finish loosening the bolt that attaches the support cable. The bolt will NOT be removable even though the threads are completely out. 6. Place an interior trim removal type tool (2), or equivalent, between the support cable end (3) and the latch (1), and pry the two apart. As the two spread apart, the toothed nut on the other side of the latch will begin to move towards the end of the bolt. 7. Once the toothed nut has moved away from the backside of the latch, use long nose pliers to grasp and twist it off of the bolt. Discard the toothed nut. 8. Remove the bolt and support cable. Notice: Due to manufacturing variation in the thickness of the latch, support cable end, and the shoulder on the bolt, a spacer (flat washer) must be used when installing the new cable. The washer will act as an extension to the shoulder on the bolt, and the outside diameter of the washer will allow it to fit inside of the opening in the cable end. This will allow the cable end to rotate freely on the bolt/latch when the tailgate is closed and prevent the support cable from getting pinched between the tailgate and the pickup box. The washer does part number listed in this bulletin MUST BE used when installing the new support cables. Its dimensions are critical for correct cable positioning when closing the tailgate and it has the corrosion protection specified by GM. DO NOT use any other washer in place of the one listed in this recall. Important: The washer does NOT replace the toothed nut removed earlier and is NOT to be installed between the latch and the tailgate. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall Tailgate Support Cable Inspection/Replacement > Page 15835 Notice: When installing the new support cable, make sure that the left side (LS) is installed on the left (driver's) side of the vehicle, and the right side (RS) is installed on the right (passenger) side. The support cables are marked with an LS or RS on the end of the cable that attaches to the tailgate. Installing a support cable on the incorrect side of the vehicle may result in the cable getting damaged when the tailgate is closed. 9. Install one new flat washer on the bolt followed by a new support cable. The end of the support cable should go over the washer and onto the shoulder of the bolt. 10. Install the bolt, flat washer, and cable assembly into the latch and tailgate. Tighten Tighten the bolt to 25 Nm (18 lb-ft). 11. If the other bolt was loosened earlier, Tighten Tighten the bolt to 25 Nm (18 lb-ft). 12. Verify that the support cable end rotates freely on the bolt. 13. Attach the opposite end of the support cable to the pickup box. 14. Repeat the procedure on the other support cable~ Important: Depending on the condition of the tailgate and related parts, one of the two new support cables (either left or right) may NOT be tight (taut) when the tailgate is fully open. This condition may be caused by several factors including a damaged hinge, pickup box, or the tailgate itself may be slightly bent due to overloading at some previous time. Replacing either or both support cables a second time will NOT correct this condition. Replacement of any additional parts to correct this condition will NOT be covered under this recall. 15. Remove the tailgate support, close, open and re-close the tailgate. Verify that the support cables fold properly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall Tailgate Support Cable Inspection/Replacement > Page 15836 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall Tailgate Support Cable Inspection/Replacement > Page 15837 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Shock / Support: > 04007B > Nov > 05 > Recall Tailgate Support Cable Inspection/Replacement > Page 15838 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Service and Repair > Linkage Replacement - Endgate Tailgate Shock / Support: Service and Repair Linkage Replacement - Endgate Linkage Replacement - Endgate Removal Procedure 1. Lower the endgate. 2. Loosen the endgate handle bolts. Refer to Handle Replacement Endgate. 3. Raise the endgate. 4. Remove the handle bezel by prying gently on the upper retainer tabs. 5. Lower and support the endgate. 6. Remove the endgate latch assembly. 7. Disengage the linkage rod from the latch assembly. 8. Remove the linkage rod (1) from the endgate handle assembly. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Service and Repair > Linkage Replacement - Endgate > Page 15841 1. Install the linkage rod to the endgate handle assembly. 2. Engage the linkage rod (1) to the latch assembly. 3. Install the endgate latch assembly. 4. Raise the endgate. 5. Install the endgate handle bezel. Pressing into place until fully seated. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the endgate handle bolts. Tighten the handle bolts to 25 N.m (18 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Service and Repair > Linkage Replacement - Endgate > Page 15842 Tailgate Shock / Support: Service and Repair Support Cable Anchor Bolt Replacement - Endgate Support Cable Anchor Bolt Replacement - Endgate Removal Procedure 1. Lower the endgate. 2. Remove the cable from the Anchor Bolt. 3. Remove the Anchor Bolt. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the Anchor Bolt. Tighten the bolt to 25 N.m(18 lb ft) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Service and Repair > Linkage Replacement - Endgate > Page 15843 2. Install the cable to the Anchor Bolt. 3. Close the endgate. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Service and Repair > Linkage Replacement - Endgate > Page 15844 Tailgate Shock / Support: Service and Repair Support Cable Replacement - Endgate Support Cable Replacement - Endgate Removal Procedure 1. Lower the end gate. 2. Remove the end gate support cable on each side from the cable restrain bolt. 3. Remove the retainer from the end gate striker. 4. Remove the end gate support cable from the end gate. Installation Procedure 1. Install the end gate support cable onto the end gate. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the latch fastener. Tighten the latch fasteners to 25 N.m (18 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Service and Repair > Linkage Replacement - Endgate > Page 15845 3. Install the end gate support cable onto cable restraint fastener. 4. Close the end gate. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Striker > Component Information > Service and Repair Tailgate Striker: Service and Repair Lock Striker Replacement - Endgate Removal Procedure 1. Open the endgate. 2. Remove the tail/turn signal lamp. 3. Remove the striker bolt. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the striker bolt. Tighten the bolt to 50 N.m (37 lb ft). 2. Install the tail/turn signal lamp. 3. Close the endgate. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Towing Hook / Bracket > Component Information > Service and Repair Towing Hook / Bracket: Service and Repair Tow Hook Replacement (25/35 Series) Removal Procedure 1. Remove the tow hook bolts from the frame rail. 2. Remove the tow hook from the vehicle. Installation Procedure 1. Install the tow hook to the frame rail. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the tow hook through the frame rail. Tighten the bolts to 85 N.m (63 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair Truck Bed: Service and Repair Pickup Box Replacement Removal Procedure 1. Disconnect the tail/turn signal lamp wiring connectors (1) at the rear lamps bussing block at the rear of the vehicle. 2. Remove the tail lamp assembly. 3. Open the fuel filler door. 4. Remove the screws and the push-pin holding the fuel filler neck to the side panel. 5. Remove the end gate. 6. Remove the pickup box fasteners (1) from the frame rails. 7. With the an assistant remove the box from the vehicle. Installation Procedure 1. Align the pickup box on the frame rails. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Page 15855 Notice: Refer to Fastener Notice in Service Precautions. 2. Loosely install the pickup box fasteners (1) to the frame rails. Tighten the retaining bolts to the frame rail to 85 N.m (63 lb ft). 3. Install the end gate. 4. Fasten the screws and the push-pin around the fuel filler neck. 5. Close the fuel filler door. 6. Install the tail lamp assembly. 7. Connect the tail lamp wiring connectors (1) at the rear lamps bussing block, at the rear of the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Remove the wiper arms. 2. Pull up in order to release the outboard air inlet grille panel clips. 3. Remove the attaching clips running along the edges of the center air inlet grille panel. 4. Remove the sheet metal screws on each end of the air inlet grille panel. 5. Disconnect the windshield washer hose from the nozzle underneath the center air inlet grille panel. 6. Remove the air inlet grille panel. Installation Procedure 1. Connect the windshield washer hose to the nozzle under the center air inlet grille panel. 2. Position the air inlet grille panel to the vehicle and attach the clips to the edges of the center air inlet grille panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the sheet metal screws on each end of the air inlet grille panel. Tighten the sheet metal screws to 2 N.m (18 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 15861 4. Align the outboard air inlet grille panel clips and press down in order to install. 5. Install the wiper arms. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Auxiliary Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Auxiliary Weatherstrip Replacement - Auxiliary Removal Procedure 1. Open the door. 2. Pull the weather-strip from the pinchweld flange. Installation Procedure 1. Push the weather-strip over the pinch-weld flange. 2. Close the door. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Auxiliary > Page 15867 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Weatherstrip Replacement - Front Door Removal Procedure 1. Open the door. 2. Remove the sill plate. 3. Remove the hinge pillar trim panel. 4. Remove the windshield pillar molding. 5. Remove the weatherstrip from the rear side door opening. Pull the unit away from channel, separating the weatherstrip from the pinchweld flange. Installation Procedure 1. Install the weatherstrip from the rear side door opening fully seating the weatherstrip into the channel. 2. Install the windshield pillar molding. 3. Install the hinge pillar trim panel. 4. Install the sill plate. 5. Check door closing effort and seal to door fit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Auxiliary > Page 15868 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Side Door Opening Weatherstrip Replacement - Side Door Opening Removal Procedure 1. Open both doors. 2. Remove the sill plate. 3. Remove the hinge pillar trim pillar. 4. Remove the windshield pillar molding. 5. Remove the weather-strip from the rear side door pinch-weld flange. Installation Procedure 1. Install the weather-strip from the rear side door opening fully seating the weather-strip into the pinch-weld flange. 2. Install the windshield pillar molding. 3. Install the hinge pillar trim pillar. 4. Install the sill plate. 5. Inspect the door closing effort and seal to door fit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel Front Door Window Glass Weatherstrip: Service and Repair Door Window Channel Window Run Channel Replacement - Front Door Removal Procedure 1. Remove the window. 2. Remove the window glass weatherstrip. 3. Remove the window run channel bolts. 4. Remove the front and the rear window run channels from the door. Installation Procedure 1. Install the front and the rear window run channels to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the front and the rear window run channel bolts. 1. Tighten the front bolt to 9 N.m (80 lb in). 2. Tighten the rear bolt to 9 N.m (80 lb in). 3. Install the window glass weatherstrip. 4. Install the window. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 15873 Front Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Front Door Window Removal Procedure 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the window. 4. Remove the screws. 5. Pull the weatherstrip from the following locations: * The front of the glass run channel * The top of the window frame flange * The rear of the glass run channel 6. Remove the weatherstrip from the door. Installation Procedure 1. Install the weatherstrip to the following locations: * The front of the glass run channel * The top of the window frame flange * The rear of the glass run channel Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts. Tighten to 6 N.m (53 lb in). 3. Install the window. 4. Install the water deflector. 5. Install the door trim panel. 6. Inspect operation of window. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 15874 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Front Door Window Belt Outer - Front Removal Procedure Important: The outer belt sealing strip seals between the inner and outer door panels and the window at the belt line. The outer sealing strip is replaceable. Do not remove the inner sealing strip, because the strip is attached to the glass run channel. 1. Lower the window. 2. Remove the outside mirror. 3. Remove the outer sealing strip from the door, lifting up on the forward end in order to unhook the rear of the strip from the window run channel. Installation Procedure 1. Hook the rear end of the sealing strip into the window run channel. Lower and press the strip into place. 2. Install the outside mirror. 3. Raise the window. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair Hood Weatherstrip: Service and Repair Seal Replacement - Hood Rear Removal Procedure Pull up on the rear hood seal and remove from the cowl pinch-weld flange. Installation Procedure Align the slot in the rear hood seal with the cowl pinch-weld flange and press into place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Auxiliary Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Auxiliary Weatherstrip Replacement - Auxiliary Removal Procedure 1. Open the door. 2. Pull the weather-strip from the pinchweld flange. Installation Procedure 1. Push the weather-strip over the pinch-weld flange. 2. Close the door. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Auxiliary > Page 15882 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Side Door Opening Weatherstrip Replacement - Side Door Opening Removal Procedure 1. Open both doors. 2. Remove the sill plate. 3. Remove the hinge pillar trim pillar. 4. Remove the windshield pillar molding. 5. Remove the weather-strip from the rear side door pinch-weld flange. Installation Procedure 1. Install the weather-strip from the rear side door opening fully seating the weather-strip into the pinch-weld flange. 2. Install the windshield pillar molding. 3. Install the hinge pillar trim pillar. 4. Install the sill plate. 5. Inspect the door closing effort and seal to door fit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Auxiliary > Page 15883 Rear Door Weatherstrip: Service and Repair Rear Door Weatherstrip Replacement Weatherstrip Replacement - Rear Door Removal Procedure 1. Open the rear door. 2. Remove the rear door sill plate. 3. Remove the center pillar molding. 4. Remove the rear quarter trim panel. 5. Remove the weatherstrip (1) from the door opening flange. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Auxiliary > Page 15884 1. Install the weatherstrip (1) to the door opening flange. 2. Install the rear quarter trim panel. 3. Install the center pillar molding. 4. Install the rear door sill plate. 5. Close the rear door. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Auxiliary > Page 15885 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door Window Weatherstrip Replacement - Rear Door Window Removal Procedure 1. Remove the window. 2. Pull the weatherstrip from the front window run channel. 3. Pull the weatherstrip from the rear window run channel. 4. Pull the weatherstrip from the window frame flange. Installation Procedure 1. Align the weatherstrip in the window frame flange. 2. Press the weatherstrip into the window frame flange until fully seated. 3. Press the weatherstrip into the rear window run channel until fully seated. 4. Press the weatherstrip into the front window run channel until fully seated. 5. Install the window. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Weatherstrip Rear Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Rear Door Window Removal Procedure 1. Remove the window. 2. Pull the weatherstrip from the front window run channel. 3. Pull the weatherstrip from the rear window run channel. 4. Pull the weatherstrip from the window frame flange. Installation Procedure 1. Align the weatherstrip in the window frame flange. 2. Press the weatherstrip into the window frame flange until fully seated. 3. Press the weatherstrip into the rear window run channel until fully seated. 4. Press the weatherstrip into the front window run channel until fully seated. 5. Install the window. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Weatherstrip > Page 15890 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Rear Door Window Belt Outer Removal Procedure Important: The outer belt sealing strip seals between the inner and outer door panels and the window at the belt line. The outer sealing strip is replaceable. Do not remove the inner sealing strip, because the strip is attached to the glass run channel. 1. Lower the window. 2. Remove the outer sealing strip from the door. Installation Procedure 1. Align the sealing strip in place. Lower and press the strip into place. 2. Raise the window. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams Cruise Control Module: Diagrams Cruise Control Module (CCM) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Page 15895 Cruise Control Module (CCM) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams Cruise Control Module: Diagrams Cruise Control Module (CCM) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Page 15903 Cruise Control Module (CCM) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15913 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15914 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15915 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15916 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15917 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15918 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15919 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15920 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15921 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15922 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15923 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15924 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15925 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15926 Audible Warning Device: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15927 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15928 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15929 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15930 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15931 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15932 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15933 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15934 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15935 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15936 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15937 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15938 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15939 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15940 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15941 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15942 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15943 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15944 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15945 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15946 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15947 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15948 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15949 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15950 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15951 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15952 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15953 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15954 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15955 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15956 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15957 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15958 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15959 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15960 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15961 Backup Alarm (With RPO Code 8S3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 15962 Audible Warning Device: Electrical Diagrams Audible Warnings diagram Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 15963 Audible Warning Device: Description and Operation AUDIBLE WARNINGS DESCRIPTION AND OPERATION The audible warnings alert the driver of a system concern or a critical vehicle condition. The radio generates the audible warnings through the left front speaker. The radio receives audible warning requests via the class 2 serial data line. If the radio receives multiple audible warning requests, the warning with the highest priority sounds first. On vehicles with an audio amplifier, the amplifier instead of the radio generates the audible warnings and receives audible warnings requests via the class 2 serial data line. Either the radio or the audio amplifier is the chime producer. The following lists the audible warning priority and the pulse rate: 1. Fast rate chime (150 pulses per min) 2. Medium rate chime (100 pulses per min) 3. Slow rate chime (50 pulses per min) 4. Turn signal reminder (will pulse at turn signal flasher rate) DOOR AJAR WARNING The chime producer activates the door ajar audible warning as requested by the instrument panel cluster (IPC). The IPC sends a class 2 message to the chime producer indicating the chime duration, 4 pulses. The door ajar warning sounds and the appropriate DOOR AJAR indicator illuminates in the driver information center (DIC) when the following occurs: The body control module (BCM) determines that a door; driver door, passenger door, left rear door, right rear door, is open, signal is low. The IPC receives a class 2 message from the BCM indicating the door ajar status. - The vehicle is not in PARK. The IPC receives a class 2 message from the powertrain control module (PCM) indicating the gear position. - The vehicle speed is greater than 8.05 km/h (5 mph). The IPC uses the vehicle speed signal circuit , 4000 pulses/mile, from the PCM in order to calculate the vehicle speed. FASTEN SAFETY BELT WARNING The inflatable restraint sensing and diagnostic module (SDM) senses that the drivers seat belt is not buckled and the signal is low. The SDM sends a class 2 message to the instrument panel cluster (IPC) requesting illumination of the seat belt indicator. The SDM sends a class 2 message to the chime producer indicating a chime at the rate of 50 pulses per minute, slow rate chime, for a duration of approximately 6 seconds. The fasten safety belt warning sounds and the seat belt indicator illuminates when the following occurs: Ignition switch transitions to ON. - The seat belt switch signal to the SDM is low. If the seat belt is buckled when the ignition is turned ON, the chime will not sound. If the seat belt is buckled while the chime is sounding, the chime stops. KEY-IN-IGNITION WARNING When the body control module (BCM) detects the key is in the ignition and the signal is low with the driver door open, it activates an audible warning. The key-in-ignition chime sounds at the rate of 100 pulses per minute, medium rate chime, until the driver door is closed or the key removed from the ignition switch. The BCM activates the key-in-ignition warning when all of the following occurs: The ignition switch is OFF. - The key-in-ignition switch signal is low. - The driver door jamb switch signal is low with the driver door open. LIGHTS ON CHIME The body control module (BCM) will activate an audible warning as a reminder that the headlamps are left ON when exiting the vehicle with the ignition switch in the OFF position. The lights ON warning sounds at the rate of 150 pulses per minute, fast rate chime, until the headlamp switch is turned OFF. The BCM receives a signal from the headlamp and panel dimmer switch via the headlamp relay. The BCM activates the lights on warning chime when the following occurs: The ignition is OFF. - The park lamp switch input is active. - The dimming potentiometer input is not in a maximum dimming state. TURN SIGNAL WARNING The body control module (BCM) activates an audible warning as a reminder that the turn signal has been on for a distance of more than 1.20 km (0.75 mi). The BCM receives the vehicle speed and distance via the vehicle speed signal circuit. The turn signal chime will use a tone that is synchronized with the turn signal flasher. The BCM will activate the turn signal chime when the following occurs: The ignition is ON. - Left or right turn signal switch is ON. - The vehicle has traveled further than 1.20 km (0.75 mi). PARK BRAKE CHIME The body control module (BCM) activates the park brake chime when the park brake is engaged and the signal circuit is low and vehicle is driven for at least 3 seconds at a speed above 4.8 km/h (3 mph). The chime will sound at the rate of 150 pulses per minute, fast rate chime. The park brake indicator will flash for any distance the vehicle is driven every half second until the park brake is no longer engaged. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 15964 ADDITIONAL WARNINGS The following warnings have an associated instrument panel cluster (IPC) indicator or driver information center (DIC) indicator: - Engine Overheated Stop Engine The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration, continuous. - Ice Possible The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration. - Liftgate Ajar/Rear Access Open The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration, 4 pulses. - Low Fuel The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency, medium rate, and duration, 4 pulses. - Oil Pressure Low Stop Engine The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration, continuous. - Overspeed/Vehicle Overspeed The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration, continuous. - Reduced Engine Power The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration. - Service Stability System The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration. - Stability System Disabled The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration. - Trans Hot Idle Engine The chime producer activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the chime producer indicating the chime frequency and duration, continuous. Refer to Indicator/Warning Message Description and Operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15969 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15970 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15971 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15972 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15973 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15974 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15975 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15976 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15977 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15978 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15979 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15980 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15981 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15982 Cigarette Lighter: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15983 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15984 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15985 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15986 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15987 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15988 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15989 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15990 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15991 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15992 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15993 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15994 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15995 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15996 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15997 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15998 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 15999 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16000 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16001 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16002 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16003 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16004 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16005 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16006 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16007 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16008 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16009 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16010 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16011 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16012 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16013 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16014 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16015 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16016 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16017 Cigarette Lighter: Connector Views Cigar Lighter (With RPO Code Y91 Or UQ3/UQ5)) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16018 Cigar Lighter (With RPO Code YE9/UQ7) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16019 Cigarette Lighter: Electrical Diagrams Cigar Lighter/Auxiliary Outlets Diagram 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16020 Cigar Lighter/Auxiliary Outlets Diagram 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16021 Cigar Lighter/Auxiliary Outlets Diagram 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16022 Cigar Lighter/Auxiliary Outlets Diagram 4 (1 Of 2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16023 Cigar Lighter/Auxiliary Outlets Diagram 4 (2 Of 2) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Description and Operation Compass: Description and Operation COMPASS The mirror uses 2 magnetic field sensors for compass direction. One sensor is for north and south, the other is for east and west. The mirror supplies a signal and low reference to each sensor. As the vehicle travels with or against the earth's magnetic pull, there will be a change in voltage on one or both sensors. As a result of the change in voltage, the mirror changes the heading on the compass display. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Description and Operation > Page 16027 Compass: Service and Repair COMPASS CALIBRATION AND VARIANCE PROCEDURE COMPASS CALIBRATION Before calibrating the compass, drive the vehicle to an open area that is magnetically clean or free of large metallic objects such as high tension power lines or large steel buildings. Verify there are no magnetized roof antennas, magnets on or hanging from the mirror, or any other magnetized objects on the inside or outside of the vehicle close to the mirror. 1. Start the engine. IMPORTANT: Before calibrating the compass, make sure the mirror has the correct zone number. Refer to Compass Magnetic Variation Adjustment. 2. Press and hold the switch for the compass, which may be depicted as COMP, COMPASS, or on/off (w/UE1) depending on the type of mirror on the vehicle, until the letter "C" or "CAL" is displayed. 3. Drive the vehicle in circles at a speed of less than 8 km/h (5 mph) until the "C" or "CAL" is replaced by a proper vehicle heading. The calibration procedure is now complete. COMPASS MAGNETIC VARIATION ADJUSTMENT Magnetic variation adjustments are required when the compass displays a constant error in heading. Variation is the difference between magnetic north and true north due to geographical location. 1. Locate your current geographic location on the World Magnetic Variation Map. 2. Turn ON the ignition, with the engine OFF. 3. Press and hold the switch for the compass, which may be depicted as COMP, COMPASS, or on/off (w/UE1) depending on the type of mirror on the vehicle, until a zone number appears on the compass display. 4. Depress the switch for the compass to select the desired zone number. 5. Wait 5 seconds. The display will return to a compass heading. The variance procedure is now complete. 6. Calibrate the compass. Refer to Compass Calibration mentioned above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling The SIR Identification Views shown below illustrate the approximate location of all SIR components available for the vehicle. This will assist in determining the appropriate SIR Disabling and Enabling for a given service procedure. Refer to See: Restraint Systems/Air Bag Systems/Locations/SIR Zone Identification Views There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: - Do not expose inflator modules to temperatures above 65°C (150°F). - Verify the correct replacement part number. Do not substitute a component from a different vehicle. - Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: - Inflatable restraint sensing and diagnostic module (SDM) - Any Inflatable restraint air bag module - Inflatable restraint steering wheel module coil - Any Inflatable restraint sensor - Inflatable restraint seat belt pretensioners - Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Important: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 16032 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Passenger Compartment Cross Beam > Component Information > Description and Operation Passenger Compartment Cross Beam: Description and Operation Magnesium Instrument Panel Support Instrument Panel Support The Instrument Panel Support is a one-piece component comprised of a magnesium steering column support (Fig. 1.21), which holds the instrumentation and steering column; a die-formed tube attaches to the passenger side and supports the dashboard. This assembly functions as a structural cross-vehicle beam, air-bag support, and instrument panel carrier, which consolidates many different steel and plastic components. The magnesium instrument panel support is designed to deform and absorb energy generated by a severe impact. NOTE: Under no circumstance is the magnesium support to be repaired in any way. If any of the following conditions are present after a collision, the magnesium support must be replaced: - Steering column capsules have released or column has collapsed. - The steel knee bolster brackets are bent. - The parts which attach to the magnesium support do not fit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Description and Operation Door/Trunk Ajar Indicator/Lamp: Description and Operation DOOR AJAR INDICATOR DESCRIPTION AND OPERATION DOOR AJAR INDICATOR SYSTEM COMPONENTS The door ajar indicator system consists of the following components: The driver door module (DDM) - The passenger front door module (PDM) - The body control module (BCM) - The instrument panel cluster (IPC) - The driver information center (DIC) - The driver door ajar switch - The passenger door ajar switch - The left rear door ajar switch - The right rear door ajar switch - The liftgate ajar switch DRIVER DOOR AJAR AND PASSENGER DOOR AJAR The DDM and PDM receive a discrete input from the respective door ajar switch to indicate the status of the door. The DDM or PDM then communicates this status to the IPC via class 2 message. The IPC, upon receipt of this class 2 message, will illuminate the appropriate door ajar message in the DIC and also send a class 2 message to the radio to activate the door ajar audible warning when the following conditions are met: The transmission is removed from PARK - The vehicle speed is greater then 8.05 km/h (5 mph) LEFT REAR DOOR AJAR AND RIGHT REAR DOOR AJAR The BCM receives a discrete inputs from both the left and right rear door and liftgate ajar switches to indicate the status of the doors and liftgate. The BCM then communicates this status to the IPC via class 2 message. The IPC, upon receipt of this class 2 message, will illuminate the appropriate door ajar message in the DIC and also send a class 2 message to the radio to activate the door ajar audible warning when the following conditions are met: The transmission is removed from PARK - The vehicle speed is greater then 8.05 km/h (5 mph) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Driver C2 Door Latch Assembly (Door Jamb Switch) - Driver C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16043 Door Latch Assembly (Door Jamb Switch) - Driver - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16044 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Front Passenger C2 Door Latch Assembly (Door Jamb Switch) - Front Passenger C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16045 Door Latch Assembly (Door Jamb Switch) - Front Passenger - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16046 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - LR C2 (Crew Cab Only) Door Latch Assembly (Door Jamb Switch) - LR C2 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16047 Door Latch Assembly (Door Jamb Switch) - LR - C2 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16048 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - RR C2 (Crew Cab Only) Door Latch Assembly (Door Jamb Switch) - RR C2 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16049 Door Latch Assembly (Door Jamb Switch) - RR - C2 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Page 16050 Door Switch: Description and Operation DOOR LATCH (DOOR JAMB) SWITCHES The theft deterrent system uses the door key switch as one method in order to activate the alarm. If the BCM detects any door opening before the BCM receives a disarm input, the alarm mode activates. DOOR KEY SWITCH The BCM monitors the door key switches in order to disarm the CTD system. When the lock cylinder turns in order to unlock the door, the switch grounds the disarm input to the BCM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Instruments - DIC Perceived Fuel Economy Settings Driver/Vehicle Information Display: Technical Service Bulletins Instruments - DIC Perceived Fuel Economy Settings Bulletin No.: 03-00-89-021 Date: July 30, 2003 INFORMATION Subject: New Vehicle Pre-Delivery Inspection - Perceived Fuel Economy and Driver Information Center (DIC) Settings Models: 2003-2004 Passenger Cars and Trucks 2003-2004 HUMMER H2 with Driver Information Center (DIC) The customer's initial perception of vehicle fuel economy, based upon the information displayed on the Driver Information Center (DIC), may contribute to poor ratings for fuel economy in various automotive surveys. The way the vehicle is handled during the build and shipping process may leave inaccurate values in the history of the DIC. During the pre-delivery inspection, the dealership must reset the "average fuel economy" setting. Reset the average fuel economy setting according to the information in the appropriate Owner's Manual. Once reset, the average fuel economy will then be calculated starting from that point. The data used to determine fuel range is an average of recent driving conditions. This setting cannot be reset. However, as the customer's driving conditions change, the data will be gradually updated to reflect more accurate readings. If a customer inquires about fuel economy, and the fuel consumption information is not on the price sticker, do not exaggerate the vehicle's capabilities. In either case, stress that fuel economy performance is highly dependent upon driving habits and vehicle usage. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 16055 Driver/Vehicle Information Display: Description and Operation DRIVER INFORMATION CENTER (DIC) DESCRIPTION AND OPERATION DRIVER INFORMATION CENTER (DIC) The driver information center (DIC) consists of a single line 22 character vacuum fluorescent (VF) display placed in the lower center area of the instrument panel cluster (IPC). The DIC will display vehicle information, configuration, and warning parameters to the driver. The display parameters are cycled, changed, and acknowledged using 4 DIC buttons. Trip Information Button representation icon appears as a road to the horizon. - Fuel Information Button representation icon appears as a gasoline pump. - Personalization Button representation icon appears as a human next to vehicle. - Select Button representation icon appears as an arrow. DIC DISPLAYS The DIC parameters are displayed by order of priority as follows (from highest to lowest) : Service Diagnostics - Driver Identifier - Feature Programming - Driver Warnings - Vehicle Information VEHICLE INFORMATION Vehicle information provides feedback to the driver on vehicle performance, mileage, maintenance, or related information. Vehicle information can only be displayed with the ignition switch in the RUN position. When the English/Metric status changes, any applicable vehicle information data values will also change. DIC TRIP INFORMATION / RESET CAPABILITIES The available DIC Trip Information and reset capabilities are as follows: Odometer - Cannot be reset - Personal Trip Odometer - Can be reset - Business Trip Odometer - Can be reset - Timer - Can be reset - Hourmeter - Cannot be reset TRIP RESET STEM The trip reset stem on the IPC operates in the following manner with the ignition switch in the RUN position: 1. Each time the trip reset stem is pushed the display will cycle to the next trip parameter. The trip parameters are as follows: - Odometer - Personal Trip odometer - Business Trip odometer - Timer - Hourmeter 2. Holding the trip reset stem for greater than 1 second or depressing the SWC Select button while either Personal Trip or Business Trip odometer is displayed will reset the displayed trip odometer and all other corresponding trip parameters to 0.0 upon release of the stem. The trip odometer will remain displayed after being reset. 3. If a trip information parameter is being displayed, pressing the DIC Trip Information button will display the next trip information parameter. 4. If the next Trip Information parameter to be displayed is Timer, Hourmeter, or blank, pressing the reset stem will return the display to the Odometer. ODOMETER The odometer is capable of displaying values from 0 - 999,999 mi or km. If the ignition is in the OFF or UNLOCK/ACC position, the odometer can be displayed by pressing the trip reset stem. The odometer will remain displayed for 5 seconds. TRIP ODOMETERS The DIC can display Personal Trip or Business Trip odometers. The trip odometers are capable of displaying values from 0 - 999999.9 mi or km. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 16056 When the maximum value is reached, the trip odometer will roll over to 0.0. TIMER The Timer is displayed as XX (hours) : XX (minutes) : XX (seconds). The Timer is started and stopped using the DIC Select button. Holding the Select button for longer than 1 second while the Timer parameter is displayed will reset the Timer to 00:00:00. The Timer status and data value is retained in memory when the ignition is turned OFF. When the ignition is turned ON again, the Timer status and data value is resumed. The Timer maximum value is 99:59:59. When the maximum is reached, the Timer rolls over to 00:00:00 and continues to operate. FUEL INFORMATION DIC Fuel Information / Reset Capabilities The available DIC Fuel Information and reset capabilities are as follows: Range. Can not be reset - Avg. Fuel Economy. Can be reset - Inst. Fuel Economy. Can not be reset - Engine Oil Life. Can be reset Range The range display is the estimated distance that the vehicle can travel under current fuel economy and fuel level conditions. This range is calculated from odometer information and class 2 messages. Fuel Range is capable of displaying values from 0-999 mi or km. Display appears as: RANGE: XXX MILES (English), RANGE: XXX km (Metric). If the range is less than 40 miles, RANGE: LOW will be displayed. Average Fuel Economy The Average Fuel Economy (AFE) value is calculated by the cluster based on Trip Distance and Trip Fuel Used. Pressing the Select button for longer than 1 second while the Average Fuel Economy is displayed in the DIC will reset to 0.0. Average Fuel Economy is capable of displaying values from 0.0-99.9. Display appears as: AVG ECON XX.X (English) MPG, AVG ECON XX.X L/100km (Metric). Trip Distance and Trip Fuel Used accumulated values are stored in memory when the ignition is turned OFF. Instantaneous Fuel Economy Instantaneous Fuel Economy values are calculated by the cluster from odometer information and class 2 messages. The cluster calculates instantaneous fuel economy based on distance and fuel. Instantaneous fuel economy is capable of displaying values from 0.0 - 99.9. Display appears as INST ECON XX.X (English), INST ECON XX.X L/100km (Metric). Values for the Instantaneous fuel economy are not stored when the ignition is turned OFF. Engine Oil Life Engine Oil Life percentage values are based on class 2 messages to the IPC. The IPC requests this value when Engine Oil Life is selected on the DIC. Engine Oil Life is capable of displaying values from 0-100 percent and the OIL LIFE RESET driver warning will be displayed. Pressing the Select button for longer than 5 seconds while Engine Oil Life is displayed on the DIC the value will reset to 100 percent. Display appears as ENGINE OIL LIFE: XXX%. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 16057 Feature Programming Refer to Personalization Description and Operation in Personalization. Driver Warnings For the list of Driver Warnings, refer to Indicator/Warning Message Description and Operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Filter Life Indicator <--> [Fuel Filter Restriction Warning Indicator] > Component Information > Service and Repair Fuel Filter Life Indicator: Service and Repair FUEL FILTER LIFE RESET This message will appear when a reset is performed either by using the steering wheel controls or the following manual procedure. For vehicles with steering wheel controls: 1. Reset the fuel filter monitor. 2. Press and hold the select button for five seconds while the "FUEL FILTER LIFE" message is displayed. This message will appear on the DIC for ten seconds. For vehicles without steering wheel controls, do the following: 1. Without pressing the pedals, turn the ignition key to the "ON" position without starting the engine. 2. Wait five seconds. 3. Completely press the brake and the accelerator pedals simultaneously and hold for ten seconds. The system is now reset. 4. Turn the ignition key off. The next time the engine is started, the message will no longer be displayed. Always reset the FUEL FILTER LIFE system after a fuel filter change. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-04-008A > Apr > 05 > Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set Fuel Gauge: Customer Interest Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set Bulletin No.: 05-06-04-008A Date: April 14, 2005 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P1172 or P2636, Fuel Gauge Reads Empty, Service Engine Soon (SES) Light On (Relocate Auxiliary Fuel Tank Vent Hose) Models: 2001-2005 Chevrolet Silverado (Cab Chassis Models Only) 2001-2005 GMC Sierra (Cab Chassis Models Only) with Auxiliary Fuel Tank Supercede: This bulletin is being revised to clarify the difference between the auxiliary fuel tank balance hose and vent hose. Please discard Corporate Bulletin Number 05-06-04-008 (Section 06 Engine/Propulsion System). Condition Some customers may comment that the SES light comes on and the fuel gauge reads empty. when This may occur when the vehicle is parked on an incline with the engine running. Diagnosis with a scan tool may reveal a DTC P1172 and/or P2636. Cause Important: A similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. The auxiliary fuel tank vent hose is located in the same "T" connection on the main tank vent hose as the auxiliary tank balance hose. During fuel transfer, the fuel is pumped out of the auxiliary tank to the main tank via the balance hose. The fuel is then sucked back into the auxiliary tank via the vent hose rather then dumping the fuel into the main tank. When the Powertrain Control Module (PCM) does not detect a fluid level transfer between the main tank and the auxiliary tank, the PCM shuts off the auxiliary tank pump and the fuel gauge goes to empty. Correction Follow the service procedure below to correct this condition. 1. Depending on the body upfitter, it may be necessary to raise the vehicle in order to gain access to the auxiliary tank balance hose. 2. Depending on the body upfitter, it may be necessary to remove the left rear tire/wheel assemblies in order to gain access to the auxiliary tank balance hose. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-04-008A > Apr > 05 > Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set > Page 16069 3. Locate the auxiliary fuel tank vent hose. The vent hose is the smaller diameter of the two hoses that comes from the auxiliary fuel tank and feeds into the main tank vent hose. 4. Disconnect the auxiliary tank vent hose from the main tank vent hose connection. 5. Install the cap supplied with kit, P/N 15213990, to the main tank vent hose connector where the auxiliary tank vent hose was just removed. 6. Locate the section of vent hose on the main tank between the fuel filler neck and the metal pipe. The smaller of the two hoses on the filler neck. 7. Cut the main tank vent hose between the filler neck and the metal pipe using an appropriate cutting tool. 8. Install the "T" and the two hose clamps supplied with kit, P/N 15213990, into the main tank vent hose. Tighten Tighten the hose clamps to 2.5 N.m (22 lb in). 9. Install the new auxiliary tank vent hose and clamp supplied with kit, P/N 15213990, to the "T" that was just installed. Tighten Tighten the hose clamp to 2.5 N.m (22 lb in). 10. Connect the new vent hose to the original auxiliary tank hose. 11. Secure the newly installed vent hose and the original auxiliary tank vent hose with plastic ties supplied in kit, P/N 15213990. 12. If necessary, reinstall the left rear tires/wheels assemblies. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-04-008A > Apr > 05 > Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set > Page 16070 13. If necessary, lower the vehicle. 14. Using a scan tool, clear the DTCs. 15. Start the vehicle and inspect for leaks. Important: Advise the customer that a similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-04-008A > Apr > 05 > Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set Fuel Gauge: All Technical Service Bulletins Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set Bulletin No.: 05-06-04-008A Date: April 14, 2005 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P1172 or P2636, Fuel Gauge Reads Empty, Service Engine Soon (SES) Light On (Relocate Auxiliary Fuel Tank Vent Hose) Models: 2001-2005 Chevrolet Silverado (Cab Chassis Models Only) 2001-2005 GMC Sierra (Cab Chassis Models Only) with Auxiliary Fuel Tank Supercede: This bulletin is being revised to clarify the difference between the auxiliary fuel tank balance hose and vent hose. Please discard Corporate Bulletin Number 05-06-04-008 (Section 06 Engine/Propulsion System). Condition Some customers may comment that the SES light comes on and the fuel gauge reads empty. when This may occur when the vehicle is parked on an incline with the engine running. Diagnosis with a scan tool may reveal a DTC P1172 and/or P2636. Cause Important: A similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. The auxiliary fuel tank vent hose is located in the same "T" connection on the main tank vent hose as the auxiliary tank balance hose. During fuel transfer, the fuel is pumped out of the auxiliary tank to the main tank via the balance hose. The fuel is then sucked back into the auxiliary tank via the vent hose rather then dumping the fuel into the main tank. When the Powertrain Control Module (PCM) does not detect a fluid level transfer between the main tank and the auxiliary tank, the PCM shuts off the auxiliary tank pump and the fuel gauge goes to empty. Correction Follow the service procedure below to correct this condition. 1. Depending on the body upfitter, it may be necessary to raise the vehicle in order to gain access to the auxiliary tank balance hose. 2. Depending on the body upfitter, it may be necessary to remove the left rear tire/wheel assemblies in order to gain access to the auxiliary tank balance hose. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-04-008A > Apr > 05 > Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set > Page 16076 3. Locate the auxiliary fuel tank vent hose. The vent hose is the smaller diameter of the two hoses that comes from the auxiliary fuel tank and feeds into the main tank vent hose. 4. Disconnect the auxiliary tank vent hose from the main tank vent hose connection. 5. Install the cap supplied with kit, P/N 15213990, to the main tank vent hose connector where the auxiliary tank vent hose was just removed. 6. Locate the section of vent hose on the main tank between the fuel filler neck and the metal pipe. The smaller of the two hoses on the filler neck. 7. Cut the main tank vent hose between the filler neck and the metal pipe using an appropriate cutting tool. 8. Install the "T" and the two hose clamps supplied with kit, P/N 15213990, into the main tank vent hose. Tighten Tighten the hose clamps to 2.5 N.m (22 lb in). 9. Install the new auxiliary tank vent hose and clamp supplied with kit, P/N 15213990, to the "T" that was just installed. Tighten Tighten the hose clamp to 2.5 N.m (22 lb in). 10. Connect the new vent hose to the original auxiliary tank hose. 11. Secure the newly installed vent hose and the original auxiliary tank vent hose with plastic ties supplied in kit, P/N 15213990. 12. If necessary, reinstall the left rear tires/wheels assemblies. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-04-008A > Apr > 05 > Fuel System - SES Lamp ON/Gauge Reads Empty/DTC's Set > Page 16077 13. If necessary, lower the vehicle. 14. Using a scan tool, clear the DTCs. 15. Start the vehicle and inspect for leaks. Important: Advise the customer that a similar condition may occur if the vehicle is fueled with the engine running AND the rear tank is fueled first. The engine must be shut off (as required by law) during vehicle refueling. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Adapter Kit: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 16083 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 16084 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 16090 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 16091 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Page 16092 Fuel Gauge: Description and Operation FUEL GAGE The IPC displays the fuel level as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the fuel level percent. The fuel gage defaults to empty if: - The PCM detects a malfunction in the fuel level sensor circuit. - The IPC detects a loss of class 2 communications with the PCM. When the fuel level is less than a pre-determined value, the low fuel indicator illuminates. Reviewing the fuel system description will further explain how the system functions. Refer to: - Fuel System Description in Computers and Control Systems - 4.3L - Fuel System Description (Pickup and Utility)Fuel System Description (Cab Chassis) in Computers and Control Systems - 4.8L, 5.3L and 6.0L - Fuel System Description in Computers and Control Systems - 6.6L - Fuel System Description in Computers and Control Systems - 8.1L Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications Fuel Gauge Sender: Specifications FUEL LEVEL SPECIFICATIONS Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications > Page 16096 The values in the table are approximate values based on information obtained from properly operating vehicles. Actual results may vary slightly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications > Page 16097 Fuel Gauge Sender: Locations Fuel Tank - Primary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications > Page 16098 Fuel Tank - Secondary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications > Page 16099 Fuel Gauge Sender: Diagrams Fuel Level Sensor - Primary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications > Page 16100 Fuel Level Sensor - Secondary W/Dual Tanks Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications > Page 16101 Fuel Level Sensor - Primary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications > Page 16102 Fuel Level Sensor - Secondary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications > Page 16103 Fuel Gauge Sender: Description and Operation FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The engine control module (ECM) sends the fuel level information via the class 2 circuit to the instrument panel cluster (IPC). This information is used for the instrument panel (I/P) fuel gage and the low fuel warning indicator, if applicable. The ECM also monitors the fuel level input for various diagnostics. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications > Page 16104 Fuel Gauge Sender: Service and Repair FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel level sensor electrical connector (1). 3. Remove the sensor retaining clip (3). 4. Squeeze the locking tangs (2) and remove the fuel level sensor. INSTALLATION PROCEDURE 1. Install the fuel level sensor. 2. Install the sensor retaining clip (3). 3. Connect the sensor electrical connector (1). 4. Install the sending unit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling The SIR Identification Views shown below illustrate the approximate location of all SIR components available for the vehicle. This will assist in determining the appropriate SIR Disabling and Enabling for a given service procedure. Refer to See: Restraint Systems/Air Bag Systems/Locations/SIR Zone Identification Views There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: - Do not expose inflator modules to temperatures above 65°C (150°F). - Verify the correct replacement part number. Do not substitute a component from a different vehicle. - Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: - Inflatable restraint sensing and diagnostic module (SDM) - Any Inflatable restraint air bag module - Inflatable restraint steering wheel module coil - Any Inflatable restraint sensor - Inflatable restraint seat belt pretensioners - Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Important: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 16109 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Locations Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Customer Interest for Low Tire Pressure Indicator: > 05-08-49-018A > May > 06 > Instruments - Service Tire Monitor Message is Displayed Low Tire Pressure Indicator: Customer Interest Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Low Tire Pressure Indicator: > 05-08-49-018A > May > 06 > Instruments - Service Tire Monitor Message is Displayed Low Tire Pressure Indicator: All Technical Service Bulletins Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Indicator - A/T > Component Information > Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: - The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-49-007 > Feb > 04 > Instruments - Trip Odometer Apparently Inoperative Odometer: Customer Interest Instruments - Trip Odometer Apparently Inoperative Bulletin No.: 04-08-49-007 Date: February 26, 2004 INFORMATION Subject: Personal Trip/Business Trip Feature - Must be On for Trip Odometer to Accumulate Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali The purpose of this bulletin is to prevent the inadvertent replacement of the instrument cluster if a customer comes in to your dealership stating that the trip odometer is inoperative or does not accumulate. For vehicles with steering wheel controls, the Personal Trip (or Business Trip) feature must be turned On in order for the trip odometer to accumulate. When the display reads Personal Trip: On (or Business Trip: On), the trip odometer shall accumulate. The Personal Trip and Business Trip features can be turned on or off by pressing the select button. Refer to Driver Information Center (DIC) in the Owner's Manual for additional information. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-49-007 > Feb > 04 > Instruments - Trip Odometer Apparently Inoperative > Page 16140 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-08-49-020D > Dec > 10 > Instruments - IPC Odometer Programming Reference Guide Odometer: All Technical Service Bulletins Instruments - IPC Odometer Programming Reference Guide INFORMATION Bulletin No.: 07-08-49-020D Date: December 06, 2010 Subject: IPC Odometer Programming Method Quick Reference Guide Models: 2003-2011 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: This bulletin applies to vehicles sold in the U.S. and Canada Only. Supercede: This bulletin is being revised to add information for the 2011 model year and add new 2011 vehicles. Please discard Corporate Bulletin Number 07-08-49-020C (Section 08 - Body and Accessories). The purpose of this bulletin is to provide a reference guide to help identify which season odometer programming method to use after replacing the instrument panel cluster (IPC). The three season odometer programming methods in use today are listed below. In addition, this reference guide lists the component where the season odometer value is stored. The season odometer value may be stored in the IPC, the driver information center (DIC) or the integrated body control module (IBCM), also commonly called a body control module (BCM). Season Odometer Programming Methods in Use Today 1. IPC reprogramming and setup using the service programming system (SPS). 2. Odometer setup at the electronic service center (ESC) when using an exchange IPC/DIC. 3. Tech 2(R) - The Tech 2 is used to set up a replacement BCM, which includes loading the odometer value that is displayed and stored in the IPC. A replacement IPC will display the previously stored vehicle odometer value, communicated from the BCM, after cycling the ignition or driving the vehicle. *The odometer programming is integrated as part of the BCM programming procedure. It is not a stand-alone event. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-08-49-020D > Dec > 10 > Instruments - IPC Odometer Programming Reference Guide > Page 16146 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-08-49-020D > Dec > 10 > Instruments - IPC Odometer Programming Reference Guide > Page 16147 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-08-49-020D > Dec > 10 > Instruments - IPC Odometer Programming Reference Guide > Page 16148 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-08-49-015D > May > 10 > Instruments - Odometer/Hour Meter Programming Procedure Odometer: All Technical Service Bulletins Instruments - Odometer/Hour Meter Programming Procedure INFORMATION Bulletin No.: 07-08-49-015D Date: May 04, 2010 Subject: Information on Instrument Panel Cluster (IPC) Odometer and Engine Hour Meter Set Up at Dealership After IPC Replacement Models: 2004-2007 Buick Rainier 2003-2006 Cadillac Escalade Models 2002-2009 Chevrolet TrailBlazer 2003-2006 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 Chevrolet Silverado Classic (12th Digit of VIN 1 or 2) 2002-2009 GMC Envoy 2003-2006 GMC Sierra, Yukon Models 2007 GMC Sierra Classic (12th Digit of VIN 1 or 2) 2002-2004 Oldsmobile Bravada 2003-2007 HUMMER H2 2005-2009 Saab 9-7X Attention: The purpose of this bulletin is to inform dealership personnel that the Instrument Panel Cluster (IPC) odometer and engine hour meter (when applicable) setting will no longer be performed at an Electronic Service Center (ESC). Dealerships will now receive IPCs with the odometer and engine hour meter not programmed. The technician will be required to note the odometer reading and engine hour (when applicable) values of the original IPC, then use the SPS application to program these values into the new IPC. Supercede: This bulletin is being revised to update the text in Steps 1, 2, 3, 4, 5, 6 and 7. Please discard Corporate Bulletin Number 07-08-49-015C (Section 08 - Body and Accessories). Background Information Previous IPC replacement procedures specify that the odometer and engine hour values be communicated to and programmed by the Electronic Service Centers (ESC) into the replacement IPC at the time the replacement is ordered. This required the vehicle to be parked after the replacement IPC is ordered so that no additional mileage can be accumulated on the vehicle while the new IPC is in transit to the dealership. Improvements to the TIS2WEB SPS application will now allow IPC odometer and engine hour programming to be performed as an additional function of the IPC programming event. This new process will allow the vehicle to be returned to the customer, if necessary, and driven while waiting for the replacement IPC to arrive at the dealership. Odometer and engine hour values will no longer be communicated to the ESC for programming purposes but ESCs still need the odometer value for warranty reporting. Dealerships will now receive a replacement IPC with the odometer and engine hour values NOT programmed. The technician will be required to note the odometer and engine hour values of the original IPC, then use the TIS2WEB SPS application to program these values into the replacement IPC. The odometer and engine hour programming will now be included as a normal part of the IPC replacement procedure in SI. Odometer and Engine Hour Programming Procedure Information - If the original IPC odometer value cannot be obtained from the customer's vehicle, follow local and federal regulations regarding unknown odometer mileage situations. - Because the odometer and engine hour values can now be read from the original IPC and programmed into the replacement IPC during the same visit, the customer's vehicle will no longer need to be parked until the replacement IPC is received from an ESC. - Avalanche, Escalade, Sierra, Silverado, H2, Suburban, Tahoe and Yukon vehicles will also require the engine hour data to be recorded for transfer to the replacement IPC. The replacement IPC may already have engine hours showing. This does not affect the IPC Setup procedure. Bravada, Envoy, Rainier and TrailBlazer vehicles do not support the calculation or display of engine hour data. - Ensure that the correct odometer value is entered when prompted. Once programming is complete, the odometer and engine hour values, when applicable cannot be changed. - By default, the application odometer entry will be set to: miles. For metric units, click the button on the left next to: Kilometers. Service Procedure Important The replacement IPC requires IPC Setup procedures and SPS programming to be performed. Legacy Pass-Thru will no longer be Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-08-49-015D > May > 10 > Instruments - Odometer/Hour Meter Programming Procedure > Page 16153 supported, only J2534. 1. BEFORE the original IPC is disconnected from the vehicle, record the odometer and engine hour values. 2. Replace the IPC with a replacement part obtained from the ESC. Refer to Instrument Cluster Replacement in SI. 3. Using the TIS2WEB SPS application, select either: J2534 Tech 2 or J2534 MDI, when available and build the vehicle. 4. Select: IPC Setup J2534. 5. After selecting IPC Setup J2534, the user will be prompted to: install the new controller. Ignore this prompt if the new IPC was already installed. This prompt is just to remind the user that this application is only for a new IPC. Important FOR 2003 FULLSIZE TRUCKS, UTILITIES AND H2, THE ENGINE MUST BE STARTED AND RUNNING PRIOR TO ENTERING THE MILEAGE AND ENGINE HOURS. After the odometer value is programmed, the engine must remain running for 6 minutes 15 seconds before the ignition can be turned off. Failure to do so will result in engine hours not being programmed and a new IPC will have to be ordered. 6. Enter the odometer and engine hour values, when applicable. By default the application will be set to miles. For metric units, click the button on the left next to: Kilometers. The IPC odometer and engine hour meter setup procedure is now complete. 7. The IPC calibration files can now be programmed into the IPC. Refer to SPS in SI. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-49-007 > Feb > 04 > Instruments - Trip Odometer Apparently Inoperative Odometer: All Technical Service Bulletins Instruments - Trip Odometer Apparently Inoperative Bulletin No.: 04-08-49-007 Date: February 26, 2004 INFORMATION Subject: Personal Trip/Business Trip Feature - Must be On for Trip Odometer to Accumulate Models: 2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2004 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2004 GMC Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali The purpose of this bulletin is to prevent the inadvertent replacement of the instrument cluster if a customer comes in to your dealership stating that the trip odometer is inoperative or does not accumulate. For vehicles with steering wheel controls, the Personal Trip (or Business Trip) feature must be turned On in order for the trip odometer to accumulate. When the display reads Personal Trip: On (or Business Trip: On), the trip odometer shall accumulate. The Personal Trip and Business Trip features can be turned on or off by pressing the select button. Refer to Driver Information Center (DIC) in the Owner's Manual for additional information. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-49-007 > Feb > 04 > Instruments - Trip Odometer Apparently Inoperative > Page 16158 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation Power Seat Control Module: All Technical Service Bulletins Interior - Erratic Memory Seat Operation Bulletin No.: 04-08-50-016C Date: August 12, 2005 TECHNICAL Subject: Memory Seat May Not Return to Requested Position (Reprogram Driver Seat Module) Models: 2003-2005 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2003-2005 GMC Sierra, Yukon, Yukon XL, Yukon Denali All with Seat FRT, Individual (Non BKT) (RPO AN3) 2003-2005 HUMMER H2 with Seat, Front Bucket Deluxe (RPO AR9) Supercede: This bulletin is being revised to update the correction information. Please discard Corporate Bulletin Number 04-08-50-016B (Section 08 - Body and Accessories). Condition Some customers may comment that with repeated cycling of the memory seat between the "exit" and one of the "presets", the position of the seat may "creep" forward or rearward out of expected adjustment. Cause There is a coding deficiency in the software for the memory seat module. Correction Technicians are to reprogram the driver seat module with an updated software calibration. The previous bulletin stated to use a service calibration that was released with TIS satellite data update version 4.5. Feedback has proved that calibration to be ineffective in eliminating the memory seat creep condition. An updated service calibration was released with TIS satellite data update version 6.5 available June 13, 2005. This new calibration has additional memory seat creep protection. As always, make sure your Tech 2(R) is updated with the latest software version. Important: After programming is complete, move the seat all the way rearward and down, then bump the seat slightly forward and up. This position will be just off the end of travel hard stops. Reset both memory seat exit positions at this position. Having the seat set at just off the hard stops will aid in reducing the creep condition. Warranty Information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 16164 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Other Service Bulletins for Odometer: > 04-08-50-016C > Aug > 05 > Interior - Erratic Memory Seat Operation > Page 16170 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Page 16171 Odometer: Description and Operation ODOMETER The IPC contains a season odometer, a trip odometer and a hourmeter. Momentarily press the trip/reset switch on the IPC in order to toggle between the season odometer, the trip odometer, and the hourmeter. Press the trip/reset switch for greater than 1 second, while the trip odometer is displayed, in order to reset the trip odometer. For vehicles with steering controls, the Personal Trip On/Off (Business Trip On/Off) must be turned On in order for the trip odometer to accumulate. When the Personal Trip On/Off (Business Trip On/Off) parameter is displayed and the select button is pressed on the steering wheel, the On/Off state of the Personal Trip (Business Trip) shall be changed to the opposite state. The IPC displays the vehicle mileage and trip mileage as determined by the IPC. The IPC calculates the mileage based on the vehicle speed signal circuit from the PCM. The odometer will display 'error' if an internal IPC memory failure is detected. The odometer can be configured to display either miles or kilometers. The odometer is capable of displaying values from 0 - 999,999 mi or km. If the ignition is in the OFF or UNLOCK/ACC position, the odometer can be displayed by pressing the trip reset stem. The odometer will remain displayed for 5 seconds. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Instruments - Oil Life Monitoring System Oil Change Reminder Lamp: Technical Service Bulletins Instruments - Oil Life Monitoring System Bulletin No.: 04-06-04-045 Date: June 22, 2004 INFORMATION Subject: Oil Life Monitoring System - PCM Reset Models: 2004 All GM Passenger Cars and Trucks Important: The Oil Life Monitoring System can be found on many General Motor's vehicles prior to 2004. Refer to SI and/or the Owner's Manual for detailed information. The purpose of this bulletin is to help technicians identify which vehicles are equipped with the oil life monitoring system. Although many General Motors vehicles prior to 2004 have been equipped with the oil life monitoring system, the 2004 model year vehicles were used as a starting point to validate the system/scan tool functionality. Customers have come to depend on the Oil Life Monitoring System found on most General Motor's vehicles to inform them when it's time for an oil change. If for any reason the PCM is replaced, it is important to access the "Percent of Oil Life Remaining" from the vehicle's current PCM PRIOR to removing the PCM. This value must be programmed into the new PCM (after it is installed in the vehicle) by using the scan tool. Note: Failure to reprogram the value to the new PCM will result in missed maintenance, which may cause damage to the engine. Important: If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to changed at 5,000 km (3,000 mi) from the last engine oil change. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Page 16176 Oil Change Reminder Lamp: Description and Operation GM OIL LIFE SYSTEM When the "CHANGE ENGINE OIL" light comes on, it means that service is required for your vehicle. Have your vehicle serviced as soon as possible within the next 1 000 km (600 miles). It is possible that, if you are driving under the best conditions, the engine oil life system may not indicate that vehicle service is necessary for over a year. However, your engine oil and filter must be changed at least once a year and at this time the system must be reset. If the engine oil life system is ever reset accidentally, you must service your vehicle within 5 000 km (3,000 miles) since your last service. Remember to reset the oil life system whenever the oil is changed. Refer to GM Oil Life System - Resetting for information on the engine Oil Life System and resetting the system. When the "CHANGE ENGINE OIL" light appears, certain services, checks and inspections are required. Required services are described in the following for "Maintenance I" and "Maintenance II." Generally, it is recommended that your first service be Maintenance I, your second service be Maintenance II and that you alternate Maintenance I and Maintenance II thereafter. However, in some cases, Maintenance II may be required more often. The engine oil life monitor will indicate when to change the engine oil - usually between 5,000 km (3,000 miles) and 16,000 km (10,000 miles) since the last oil change. Under severe conditions, the "CHANGE OIL SOON" light may be displayed before 5,000 km (3,000 miles). The vehicle must not be driven more than 16,000 km (10,000 miles) or 12 months without an oil change. The engine oil life monitor will not detect dust in the oil. If the vehicle is driven in a dusty area, be sure to change the oil every 5,000 km (3,000 miles) or sooner if the "CHANGE OIL SOON" light is displayed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Page 16177 Oil Change Reminder Lamp: Service and Repair HOW TO RESET THE CHANGE ENGINE OIL MESSAGE The GM Oil Life System calculates when to change your engine oil and filter based on vehicle use. Anytime your oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where you change your oil prior to a "CHANGE ENGINE OIL" message being turned on, reset the system. To reset the "CHANGE ENGINE OIL" message, do the following: Without Driver Information Center (DIC) 1. Turn the ignition key to "RUN" with the engine off. 2. Fully press and release the accelerator pedal three times within five seconds. If the "OIL LIFE RESET" message flashes for 10 seconds, the system is resetting. 3. Turn the key to "LOCK". 4. If the "CHANGE ENGINE OIL" message comes back on when you start your vehicle, the engine oil life system has not reset. Repeat the procedure. With Driver Information Center (DIC) 1. To reset the Oil Life System use the fuel button to reach the "ENGINE OIL LIFE" screen and then press and hold the "select" button for five seconds while "ENGINE OIL LIFE" is displayed. "OIL LIFE RESET" will appear on the display for 10 seconds to let you know the system is reset. WHAT TO DO WITH USED OIL Used engine oil contains certain elements that may be unhealthy for your skin and could even cause cancer. Do not let used oil stay on your skin for very long. Clean your skin and nails with soap and water, or a good hand cleaner. Wash or properly dispose of clothing or rags containing used engine oil. See the manufacturer's warnings about the use and disposal of oil products. Used oil can be a threat to the environment. If you change your own oil, be sure to drain all the oil from the filter before disposal. Never dispose of oil by putting it in the trash, pouring it on the ground, into sewers, or into streams or bodies of water. Instead, recycle it by taking it to a place that collects used oil. If you have a problem properly disposing of your used oil, ask your dealer, a service station or a local recycling center for help. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Left Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 16181 Left Side of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 16182 Oil Pressure Sender: Diagrams Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Locations Air Temperature Sensor - Outside Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Locations > Page 16187 Ambient Air Temperature Sensor - Outside Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Locations > Page 16188 Outside Temperature Display Sensor: Service and Repair AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the radiator grille from the vehicle. 2. Remove the push pin retainer from the sensor mounted on the radiator support brace. 3. Disconnect the electrical connector from the sensor. INSTALLATION PROCEDURE 1. Connect the electrical connector to the sensor. 2. Install the sensor to the radiator support brace and install the push pin retainer. 3. Install the radiator grille to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Remove the MID-bussed electrical center from the bracket. 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch mounting bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Service and Repair > Page 16192 1. Install the park brake warning lamp switch. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake warning lamp switch mounting bolt. ^ Tighten the bolt to 3 Nm (25 inch lbs.). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the MID-bussed electrical center to the bracket. 5. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation FASTEN SAFETY BELT INDICATOR The fasten safety belt indicator may only be illuminated during RUN. The instrument panel cluster (IPC) illuminates the fasten safety belt indicator under the following conditions: - During bulb check. - The inflatable restraint sensing and diagnostic module (SDM) sends the status of the driver's seat belt switch to the IPC via a class 2 message. If the driver's seat belt is unfastened, the IPC will illuminate the fasten safety belt indicator for 72 seconds or until the driver's seat belt is fastened. If the driver's seat belt is unfastened within 8 seconds following the bulb check, the IPC will send a class 2 serial message requesting 5 chimes to sound. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Driver C2 Door Latch Assembly (Door Jamb Switch) - Driver C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16201 Door Latch Assembly (Door Jamb Switch) - Driver - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16202 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Front Passenger C2 Door Latch Assembly (Door Jamb Switch) - Front Passenger C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16203 Door Latch Assembly (Door Jamb Switch) - Front Passenger - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16204 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - LR C2 (Crew Cab Only) Door Latch Assembly (Door Jamb Switch) - LR C2 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16205 Door Latch Assembly (Door Jamb Switch) - LR - C2 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16206 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - RR C2 (Crew Cab Only) Door Latch Assembly (Door Jamb Switch) - RR C2 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16207 Door Latch Assembly (Door Jamb Switch) - RR - C2 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 16208 Door Switch: Description and Operation DOOR LATCH (DOOR JAMB) SWITCHES The theft deterrent system uses the door key switch as one method in order to activate the alarm. If the BCM detects any door opening before the BCM receives a disarm input, the alarm mode activates. DOOR KEY SWITCH The BCM monitors the door key switches in order to disarm the CTD system. When the lock cylinder turns in order to unlock the door, the switch grounds the disarm input to the BCM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications Fuel Gauge Sender: Specifications FUEL LEVEL SPECIFICATIONS Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 16212 The values in the table are approximate values based on information obtained from properly operating vehicles. Actual results may vary slightly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 16213 Fuel Gauge Sender: Locations Fuel Tank - Primary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 16214 Fuel Tank - Secondary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 16215 Fuel Gauge Sender: Diagrams Fuel Level Sensor - Primary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 16216 Fuel Level Sensor - Secondary W/Dual Tanks Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 16217 Fuel Level Sensor - Primary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 16218 Fuel Level Sensor - Secondary Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 16219 Fuel Gauge Sender: Description and Operation FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The engine control module (ECM) sends the fuel level information via the class 2 circuit to the instrument panel cluster (IPC). This information is used for the instrument panel (I/P) fuel gage and the low fuel warning indicator, if applicable. The ECM also monitors the fuel level input for various diagnostics. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 16220 Fuel Gauge Sender: Service and Repair FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the sending unit. 2. Disconnect the fuel level sensor electrical connector (1). 3. Remove the sensor retaining clip (3). 4. Squeeze the locking tangs (2) and remove the fuel level sensor. INSTALLATION PROCEDURE 1. Install the fuel level sensor. 2. Install the sensor retaining clip (3). 3. Connect the sensor electrical connector (1). 4. Install the sending unit. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Locations Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations Air Temperature Sensor - Outside Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations > Page 16227 Ambient Air Temperature Sensor - Outside Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations > Page 16228 Outside Temperature Display Sensor: Service and Repair AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the radiator grille from the vehicle. 2. Remove the push pin retainer from the sensor mounted on the radiator support brace. 3. Disconnect the electrical connector from the sensor. INSTALLATION PROCEDURE 1. Connect the electrical connector to the sensor. 2. Install the sensor to the radiator support brace and install the push pin retainer. 3. Install the radiator grille to the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Caution: Refer to Battery Disconnect Caution in Service Precautions. Disconnect the negative battery cable. 2. Remove the MID-bussed electrical center from the bracket. 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch mounting bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Page 16232 1. Install the park brake warning lamp switch. 2. Notice: Refer to Fastener Notice in Service Precautions. Install the park brake warning lamp switch mounting bolt. ^ Tighten the bolt to 3 Nm (25 inch lbs.). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the MID-bussed electrical center to the bracket. 5. Connect the negative battery cable. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations Water In Fuel Sensor: Locations Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 16236 Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 16237 Water In Fuel (WIF) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Service and Repair > Water-In-Fuel Sensor Replacement Water In Fuel Sensor: Service and Repair Water-In-Fuel Sensor Replacement WATER-IN-FUEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Drain the fuel from the fuel filter. Refer to Water-in-Fuel Draining Procedure. 2. Remove the right front wheelhouse panel. 3. Disconnect the fuel filter electrical connectors. 4. Remove the water-in-fuel sensor (3) from the fuel filter (2). INSTALLATION PROCEDURE IMPORTANT: The water-in-fuel sensor must ONLY be tightened by hand. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Service and Repair > Water-In-Fuel Sensor Replacement > Page 16240 1. Install the water-in-fuel sensor (3) to the fuel filter (2). 2. Connect the fuel filter electrical connector. 3. Install the right front wheelhouse panel. 4. Prime the fuel system. Refer to Fuel System Priming. 5. Start the engine. If the engine stalls, repeat the above step. 6. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Service and Repair > Water-In-Fuel Sensor Replacement > Page 16241 Water In Fuel Sensor: Service and Repair Water-In-Fuel Draining Procedure WATER-IN-FUEL DRAINING PROCEDURE 1. Attach a small piece of hose to the drain cock onto the water-in-fuel sensor. 2. Place an approved fuel-resistant container under the fuel filter. 3. Open the drain cock 3 or 4 turns or until the water contaminated fuel seeps from the drain cock. 4. Operate the priming pump until only diesel fuel is visible. Allow the pump to return upward between pushes. 5. Tighten the drain cock. 6. Remove the container and hose. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation PRNDL DISPLAY The IPC displays the selected gear position as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the gear position. The PRNDL display blanks if: - The IPC receives a class 2 message indicating the park position and the column park switch indicates a position other than park, open input. - The IPC detects a loss of class 2 communications with the PCM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation Speedometer Head: Description and Operation SPEEDOMETER The IPC displays the vehicle speed on the analog speedometer based on the vehicle speed signal from the PCM. The PCM converts the data from the vehicle speed sensor to a 4,000 pulses/mile signal. The IPC uses the vehicle speed signal circuit from the PCM in order to calculate the vehicle speed. The speedometer defaults to 0 km/h (0 mph) if a malfunction in the vehicle speed signal circuit exists. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Description and Operation Tachometer: Description and Operation TACHOMETER The IPC displays the engine speed on the analog tachometer based on the engine speed signal from the PCM. The IPC uses the engine speed signal circuit - 2 pulses/engine revolution - from the PCM in order to calculate the engine speed. The tachometer defaults to 0 RPM if a malfunction in the engine speed signal circuit exists. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Customer Interest for Low Tire Pressure Indicator: > 05-08-49-018A > May > 06 > Instruments - Service Tire Monitor Message is Displayed Low Tire Pressure Indicator: Customer Interest Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Low Tire Pressure Indicator: > 05-08-49-018A > May > 06 > Instruments - Service Tire Monitor Message is Displayed Low Tire Pressure Indicator: All Technical Service Bulletins Instruments - Service Tire Monitor Message is Displayed Bulletin No.: 05-08-49-018A Date: May 11, 2006 ADVANCE SERVICE INFORMATION RESOLUTION Subject: EI 05065 - Service Tire Monitor Message Displayed (Pull/Reinstall IPC Fuse or Verify Correct Passenger Door Module (PDM) and Tires) Models: 2004 Chevrolet Silverado 2004 GMC Sierra Supercede: This bulletin is being revised to provide correction action. Please discard Corporate Bulletin Number 05-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment that the "SERVICE TIRE MONITOR" message is being displayed on the DIC. Correction DO NOT REPLACE THE INSTRUMENT PANEL CLUSTER. If the DIC is displaying the SERVICE TIRE MONITOR message: 1. Verify if the vehicle has an electronic aftermarket module spliced into the ALDL Class 2 data line (purple wire). 2. If the vehicle HAS an aftermarket module spliced into the Class 2 line, pull the IPC fuse (located underhood) for 25 seconds. Important: Due to the electronic aftermarket module, the SERVICE TIRE MONITOR message may reoccur. 3. Reinstall the IPC fuse. This will clear the SERVICE TIRE MONITOR message from the display. 4. If the vehicle DOES NOT have an aftermarket module spliced into the Class 2 line, verify the vehicle is equipped with the correct PDM (Passenger Door Module) and tires. Warrant Information This repair is not covered under the vehicle warranty due to the installation of an aftermarket module. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 16277 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Technical Service Bulletins > Instruments - Reduced PRNDL Display Visibility Transmission Shift Position Indicator Lamp: Technical Service Bulletins Instruments - Reduced PRNDL Display Visibility Bulletin No.: 02-08-42-004A Date: March 30, 2007 INFORMATION Subject: PRNDL Display Reduced Visibility For Approximately One Minute Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Headlamp Control and Vacuum Fluorescent PRNDL Indicator Instrument Panel Cluster Supercede: This bulletin is being revised to include additional models and model years. Please discard Corporate Bulletin Number 02-08-42-0004 (Section 08 - Body and Accessories). After backing the vehicle out of a garage or dark environment into a daylight environment, the PRNDL display has reduced visibility for approximately one minute. While the vehicle is parked in a dark environment, the sensor for the automatic headlamp/driving lamps senses that it is dark. When the key is turned to the run/start position, the automatic headlamp module will turn all driving lamps, the instrument panel cluster and PRNDL display ON in the night-time mode. The night-time mode intensity of the instrument panel lamps and PRNDL display is controlled by the automatic headlamp module and can be dimmed further by the customer using the dimming control of the headlamp switch. When the customer then moves the vehicle from the dark environment into the bright sunlight, it will take approximately one minute before the headlamp control module recognizes this as true daylight and not just a bright overhead street lamp shining on the sensor. The headlamp control module will then turn the headlamps off and restore the instrument panel and PRNDL display to full brilliance. Without the time delay, the automatic headlamp control module would switch to the night mode (turn on all driving lamps, instrument panel lamps and PRNDL display would dim) each time the vehicle was driven under an overpass or other darkened environment. This is a normal condition and no repair should be attempted. Ensure the instrument panel backlighting control is in the full bright position. This will help alleviate the condition. You may demonstrate to the customer what happens by placing a repair order over the automatic headlamp control light sensor, which will cause the automatic headlamp control module to switch to the night mode in approximately one minute. All driving lamps will come ON, the instrument panel backlight will be dim, and the PRNDL display will also dim to the night setting in conjunction with the position of the headlamp switch dimming control. Demonstrate to the customer the variance in the instrument panel backlighting and PRNDL display while adjusting the headlamp switch dimming control to both ends of its allowable range. Advise the customer to keep the headlight switch dimming control in the highest position to allow viewing of the PRNDL display in a bright environment. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Description and Operation Volt Meter Gauge: Description and Operation VOLTMETER The IPC displays the system voltage as detected at the ignition 1 input of the IPC. When the engine is ON, the gage should be between 10-16 volts. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Water In Fuel Indicator > Water In Fuel Sensor > Component Information > Locations Water In Fuel Sensor: Locations Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Water In Fuel Indicator > Water In Fuel Sensor > Component Information > Locations > Page 16289 Top of the Engine Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Water In Fuel Indicator > Water In Fuel Sensor > Component Information > Locations > Page 16290 Water In Fuel (WIF) Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Water In Fuel Indicator > Water In Fuel Sensor > Component Information > Service and Repair > Water-In-Fuel Sensor Replacement Water In Fuel Sensor: Service and Repair Water-In-Fuel Sensor Replacement WATER-IN-FUEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Drain the fuel from the fuel filter. Refer to Water-in-Fuel Draining Procedure. 2. Remove the right front wheelhouse panel. 3. Disconnect the fuel filter electrical connectors. 4. Remove the water-in-fuel sensor (3) from the fuel filter (2). INSTALLATION PROCEDURE IMPORTANT: The water-in-fuel sensor must ONLY be tightened by hand. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Water In Fuel Indicator > Water In Fuel Sensor > Component Information > Service and Repair > Water-In-Fuel Sensor Replacement > Page 16293 1. Install the water-in-fuel sensor (3) to the fuel filter (2). 2. Connect the fuel filter electrical connector. 3. Install the right front wheelhouse panel. 4. Prime the fuel system. Refer to Fuel System Priming. 5. Start the engine. If the engine stalls, repeat the above step. 6. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Water In Fuel Indicator > Water In Fuel Sensor > Component Information > Service and Repair > Water-In-Fuel Sensor Replacement > Page 16294 Water In Fuel Sensor: Service and Repair Water-In-Fuel Draining Procedure WATER-IN-FUEL DRAINING PROCEDURE 1. Attach a small piece of hose to the drain cock onto the water-in-fuel sensor. 2. Place an approved fuel-resistant container under the fuel filter. 3. Open the drain cock 3 or 4 turns or until the water contaminated fuel seeps from the drain cock. 4. Operate the priming pump until only diesel fuel is visible. Allow the pump to return upward between pushes. 5. Tighten the drain cock. 6. Remove the container and hose. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ambient Light Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 16299 Ambient Light Sensor: Diagrams Ambient Light Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 16300 Ambient Light Sensor (With RPO Code CJ3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 16301 Ambient Light Sensor: Service and Repair AMBIENT LIGHT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel top cover. 2. Disconnect the electrical connector (1) to the ambient light sensor on the underside of the IP top cover. 3. Turn the ambient light sensor 1/4 turn and remove it from the IP top cover. INSTALLATION PROCEDURE 1. Install the ambient light sensor to the underside of the IP top cover, turning it 1/4 turn to secure it in place. 2. Connect the electrical connector (1) to the ambient light sensor on the underside of the IP top cover. 3. Install the instrument panel top cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams Backup Lamp - Switch (Manual Trans) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Service and Repair > NV 3500 Backup Lamp Switch: Service and Repair NV 3500 Backup Lamp Switch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the backup lamp switch electrical connector (3). 3. Remove the backup lamp switch. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Important: The backup lamp switch has pre-applied thread sealant on the threads. Install the backup lamp switch. ^ Tighten the switch to 37 Nm (27 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Service and Repair > NV 3500 > Page 16308 2. Connect the backup lamp switch electrical connector (3). 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Service and Repair > NV 3500 > Page 16309 Backup Lamp Switch: Service and Repair NV 4500 Backup Lamp Switch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the backup lamp switch electrical connector (1). 3. Remove the backup lamp switch and seal. Installation Procedure 1. Ensure the seal is installed on the switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the backup lamp switch. ^ Tighten the switch to 28 Nm (21 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Service and Repair > NV 3500 > Page 16310 3. Connect the backup lamp switch electrical connector (1). 4. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Service and Repair > NV 3500 > Page 16311 Backup Lamp Switch: Service and Repair ZF S6-650 Backup Lamp Switch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. If equipped with a 6.6L engine, disconnect the backup lamp switch electrical connector (3). 2. If equipped with a 8.1L engine, disconnect the backup lamp switch electrical connector (4). 3. Remove the backup lamp switch. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Service and Repair > NV 3500 > Page 16312 1. Notice: Refer to Fastener Notice in Service Precautions. Install the backup lamp switch. ^ Tighten the switch to 20 Nm (15 ft. lbs.). 2. If equipped with a 8.1L engine, connect the backup lamp switch electrical connector (4). 3. If equipped with a 6.6L engine, connect the backup lamp switch electrical connector (3). Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Brake Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 16317 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Connector Views Brake Lamp: Connector Views Tail/Stop Lamp - Left Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Connector Views > Page 16320 Tail/Stop Lamp - Right Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Page 16321 Brake Lamp: Description and Operation STOP LAMPS The STOP LP 25-amp fuse in the underhood fuse block supplies battery positive voltage to the normally open stop lamp switch. When the driver presses the brake pedal, the switch contacts close and battery positive voltage is supplied to both the STOP 15-amp fuse and the center high mounted stop lamp (CHMSL) 10-amp fuse in the instrument panel (I/P) fuse block, and to the turn signal/hazard module. The turn signal/hazard module then supplies voltage to both of the trailer rear turn/stop lamp supply voltage circuits. The voltage from the CHMSL 10-amp fuse is to the CHMSL and the trailer jumper harness. The voltage from the STOP 15-amp fuse is to the stop lamps, throttle actuator control (TAC) module, and the cruise control. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations ABS Component Views Stoplamp Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 16325 Brake Light Switch: Diagrams Stop Lamp Switch Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 16326 Stop Lamp Switch Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 16327 Brake Light Switch: Service and Repair STOP LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the stop lamp switch (2). 2. Remove the pushrod retaining clip (4). 3. Remove the stop lamp switch (2). INSTALLATION PROCEDURE 1. Install the stop lamp switch (2). 2. Install the pushrod retaining clip (4). 3. Connect the electrical connector to the stop lamp switch (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Locations Instrument Panel Switches-LH Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Switch > Component Information > Locations > Page 16332 Cargo Lamp Switch: Service and Repair LAMP SWITCH ASSEMBLY REPLACEMENT - FRONT FOG LAMP AND CARGO LAMP REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Remove the fog lamp switch and cargo switch from the housing. 3. Disconnect the electrical connector(s) from the fog lamp switch. 4. Remove the fog lamp and cargo lamp switch from the housing. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the fog lamp and cargo lamp switch. 2. Install the fog lamp switch into the housing. 3. Install the IP trim bezel to the instrument panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Page 16336 Center Mounted Brake Lamp: Service and Repair HIGH MOUNTED STOP LAMP REPLACEMENT REMOVAL PROCEDURE 1. Ensure the headlamp switch is in the OFF position. 2. Remove the high mounted stop lamp screws. 3. Remove the high mounted stop lamp from the vehicle. 4. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the high mounted stop lamp to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the high mounted stop lamp screws. Tighten Tighten the high mounted stop lamp screws to 2 N.m (17 lb in). 4. Inspect the operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams Clearance Lamp: Diagrams Clearance Lamp - LF (With RPO Code NY5 Or E63) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Page 16340 Clearance Lamp - LR (With RPO Code NYS Or E63) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Page 16341 Clearance Lamp - RF (With RPO Code NYS Or E63) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Page 16342 Clearance Lamp - RR (With RPO Code NYS Or E63) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Page 16343 Clearance Lamps - Roof (With RPo Code U01) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Page 16344 Clearance Lamp: Description and Operation CLEARANCE LAMPS The clearance lamps, are turned ON when the headlamp switch is placed in the PARK or HEAD position or anytime the headlamps are requested. The underhood fuse block supplies battery positive voltage to both the park lamp relay switch contacts and the park lamp coil circuit. The body control module (BCM) provides a ground or control circuit to the park lamp relay coil circuit. When the park lamps are turned ON, the BCM energizes the park lamp relay. Current flow is from the park lamp relay to the INT PRK 10-amp fuse, and to the clearance and roof lamps. If the headlamp switch is left in the ON position, the inadvertent power control feature will turn OFF the park, tail and clearance lamps approximately 10 minutes after the ignition switch is turned to the OFF position. If the driver places the headlamp switch in the ON position after the ignition switch has been turned OFF, or if the ignition switch is in the ACCY position, the park, tail and marker lamps will remain ON until turned OFF or the battery runs dead. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair INSTRUMENT PANEL (I/P) COMPARTMENT LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Lower the instrument panel storage compartment door by pressing in the tab. 2. With one hand holding the plunger of the switch, use a small screw driver to push in the tabs on each side while pulling outwards. 3. Pull the switch assembly from the I/P. 4. Disconnect the electrical connector. 5. Remove the bulb (1). INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Service and Repair > Page 16349 1. Install the bulb (1) into the socket. 2. Connect the electrical connector. 3. Install the switch until the tabs (1) click in place. 4. Close the compartment door. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Connector Views Daytime Running Lamp: Connector Views Daytime Running Lamp (DRL) - Left (Domestic) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Connector Views > Page 16354 Daytime Running Lamp (DRL) - Left (Export) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Connector Views > Page 16355 Daytime Running Lamp (DRL) - Right (Domestic) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Connector Views > Page 16356 Daytime Running Lamp (DRL) - Right (Export) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Page 16357 Daytime Running Lamp: Description and Operation DAYTIME RUNNING LAMPS (DRL) The daytime running lamps (DRL) will operate when the ignition switch is in the RUN position, for automatic transmissions (A/T), the gear selector is not in the PARK position, the headlamp switch is in the AUTO position, and for manual transmissions (M/T), the park brake is released. When these conditions have been met and the ambient light sensor indicates daytime conditions, the DRL will illuminate. The ambient light sensor is a light sensitive transistor that varies its voltage signal to the body control module (BCM) in response to changes to the outside (ambient) light level. When the BCM receives this signal it will either turn on the DRL or the headlamps for auto headlamp operation. Any function or condition that turns on the headlights will cancel the daytime running lamps operation. The DRL can be manually turned OFF by depressing the AHL/DRL switch in the headlamp switch. The AHL/DRL defeat switch sends a ground signal through the DRL switch signal circuit to the BCM. The BCM then turns OFF the DRL and headlamps switch to manual control. When the AHL/DRL are manually turned OFF at the headlamp switch, the AHL/DRL will default to ON with the next ignition cycle. The DRL are separate lamps independent of the headlamps. With the headlight switch in the AUTO position, the DRL will either be turned ON or OFF, after an approximate 8-second delay depending on whether daylight or low light conditions are sensed. The DRL 10-amp fuse in the underhood fuse block supplies battery positive voltage to the DRL relay switch contacts and relay coil. When the BCM energizes the DRL relay , the DRL receive voltage on the DRL supply voltage circuit. Ground for the DRL is at G100. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams Dome Lamp - Rear (Except Crew Cab With RPO Code YE9) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Page 16361 Dome Lamp: Service and Repair DOME LAMP REPLACEMENT REMOVAL PROCEDURE 1. Remove the lamp lens assembly using a small screw driver. 2. Remove the dome lamp assembly from the headliner. 3. Disconnect the electrical connector. 4. Remove the bulb. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Page 16362 INSTALLATION PROCEDURE 1. Install the bulb. 2. Connect the electrical connector. 3. Install the dome lamp assembly into the headliner. 4. Press the lens into place. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Driver C2 Door Latch Assembly (Door Jamb Switch) - Driver C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16367 Door Latch Assembly (Door Jamb Switch) - Driver - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16368 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Front Passenger C2 Door Latch Assembly (Door Jamb Switch) - Front Passenger C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16369 Door Latch Assembly (Door Jamb Switch) - Front Passenger - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16370 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - LR C2 (Crew Cab Only) Door Latch Assembly (Door Jamb Switch) - LR C2 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16371 Door Latch Assembly (Door Jamb Switch) - LR - C2 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16372 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - RR C2 (Crew Cab Only) Door Latch Assembly (Door Jamb Switch) - RR C2 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16373 Door Latch Assembly (Door Jamb Switch) - RR - C2 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Page 16374 Door Switch: Description and Operation DOOR LATCH (DOOR JAMB) SWITCHES The theft deterrent system uses the door key switch as one method in order to activate the alarm. If the BCM detects any door opening before the BCM receives a disarm input, the alarm mode activates. DOOR KEY SWITCH The BCM monitors the door key switches in order to disarm the CTD system. When the lock cylinder turns in order to unlock the door, the switch grounds the disarm input to the BCM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Exterior Lighting Relay > Component Information > Diagrams Roof Beacon Relay (With RPO Code 5X7, 5G4, TRW, Or 5Y0) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair > Fog Lamp Bulb Replacement - Front (Old Style) Fog/Driving Lamp Bulb: Service and Repair Fog Lamp Bulb Replacement - Front (Old Style) FOG LAMP BULB REPLACEMENT - FRONT (OLD STYLE) REMOVAL PROCEDURE 1. Remove the electrical connector. CAUTION: Refer to Halogen Bulb Caution in Service Precautions. 2. Remove the bulb from the fog lamp assembly by twisting the bulb counterclockwise and pulling the bulb out. INSTALLATION PROCEDURE 1. Install the bulb to the fog lamp assembly by inserting the bulb and twisting the bulb clockwise. 2. Install the electrical connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair > Fog Lamp Bulb Replacement - Front (Old Style) > Page 16384 Fog/Driving Lamp Bulb: Service and Repair Fog Lamp Bulb Replacement - Rear FOG LAMP BULB REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the rear fog lamp lens (1) retaining screws (2). CAUTION: Refer to Halogen Bulb Caution in Service Precautions. 2. Remove the bulb from the rear fog lamp assembly by twisting the bulb counterclockwise and pulling the bulb out. INSTALLATION PROCEDURE 1. Install the bulb to the rear fog lamp assembly by inserting the bulb and twisting the bulb clockwise. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear fog lamp lens (1) retaining screws (2). Tighten Tighten the screws (2) to 2 N.m (18 lb in). 3. Inspect the operation of the rear fog lamp. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations Fog/Driving Lamp Switch: Locations Instrument Panel Switches-LH Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations > Page 16388 Accessory Switch Housing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations > Page 16389 Fog Lamp Switch Rear (With RPO Code T79) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Service and Repair > Lamp Switch Assembly Replacement-Front Fog Lamp and Cargo Lamp Fog/Driving Lamp Switch: Service and Repair Lamp Switch Assembly Replacement-Front Fog Lamp and Cargo Lamp LAMP SWITCH ASSEMBLY REPLACEMENT - FRONT FOG LAMP AND CARGO LAMP REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Remove the fog lamp switch and cargo switch from the housing. 3. Disconnect the electrical connector(s) from the fog lamp switch. 4. Remove the fog lamp and cargo lamp switch from the housing. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the fog lamp and cargo lamp switch. 2. Install the fog lamp switch into the housing. 3. Install the IP trim bezel to the instrument panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Service and Repair > Lamp Switch Assembly Replacement-Front Fog Lamp and Cargo Lamp > Page 16392 Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement - Rear FOG LAMP SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the instrument panel bezel. 2. Pull out the accessary switch housing. 3. Disconnect the electrical connectors. 4. Remove the fog lamp switch from the accessary switch housing. INSTALLATION PROCEDURE 1. Install the fog lamp switch into accessary switch housing. 2. Connect the electrical connectors. 3. Install the accessary switch housing. 4. Install the instrument panel bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Service and Repair Hazard Warning Flasher: Service and Repair HAZARD AND TURN SIGNAL FLASHER REPLACEMENT REMOVAL PROCEDURE 1. Remove the knee bolster. 2. On the back side of the fuse block release the retainer while pulling the flasher (1) outwards. 3. Remove the flasher (1) from the fuse block. INSTALLATION PROCEDURE 1. Install the flasher (1) to the fuse block until the retainer clicks into place. 2. Install the knee bolster. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations Hazard Warning Switch: Locations Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 16400 Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair HEADLAMP ASSEMBLY OR HEADLAMP BULB REPLACEMENT (OLD STYLE) REMOVAL PROCEDURE CAUTION: Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter into flying glass fragments. To help avoid personal injury: Turn off the lamp switch and allow the bulb to cool before changing the bulb. - Leave the lamp switch OFF until the bulb change is complete. - Always wear eye protection when changing a halogen bulb. - Handle the bulb only by its base. Avoid touching the glass. - Keep dirt and moisture off the bulb. - Properly dispose of the used bulb. - Keep halogen bulbs out of the reach of children. NOTE: Avoid touching the bulb or letting the bulb come in contact with anything damp. Oil from your skin or moisture on the bulb can cause the bulb to explode when the bulb is turned on. If either comes in contact with the bulb, clean the bulb with alcohol or a suitable degreaser and wipe the bulb dry. 1. Open the hood. Rotate the headlamp retainer pins. 2. Remove the headlamp retainer pins. 3. Pull out the headlamp assembly in order to access the electrical connector. 4. Disconnect the electrical connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Page 16405 5. Remove the bulb from the headlamp assembly by twisting the bulb counterclockwise. INSTALLATION PROCEDURE IMPORTANT: Replace a high beam bulb with another high beam bulb. The high beam bulb has a red gasket. - Replace a low beam bulb with another low beam bulb. The low beam bulb has a gray tip and a yellow gasket at the base. 1. Install the new bulb to the headlamp assembly by twisting the bulb clockwise in order to lock in place. 2. Connect the electrical connector to the bulb. 3. Install the headlamp assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Page 16406 4. Install the headlamp retainer pins. 5. Rotate and lock the pins in place. 6. Inspect the operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Alignment Actuator > Component Information > Diagrams Headlamp Alignment Actuator: Diagrams Headlamp Leveling Actuator - Left (Export) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Alignment Actuator > Component Information > Diagrams > Page 16410 Headlamp Leveling Actuator - Right (Export) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Alignment Switch > Component Information > Diagrams Headlamp Leveling Switch (Export) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Alignment Switch > Component Information > Diagrams > Page 16414 Headlamp Alignment Switch: Service and Repair HEADLAMP LEVELING SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel bezel. 2. Pull out the accessary switch housing. 3. Disconnect the electrical connectors. 4. Remove the head lamp leveling switch from the accessary switch housing. INSTALLATION PROCEDURE 1. Install the head lamp leveling switch into accessary switch housing. 2. Connect the electrical connectors. 3. Install the accessary switch housing. 4. Install the instrument panel bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations Instrument Panel Switches-LH Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Lens > Component Information > Technical Service Bulletins > Lighting - Headlamp Polycarbonate Lens Damage Prevention Headlamp Lens: Technical Service Bulletins Lighting - Headlamp Polycarbonate Lens Damage Prevention INFORMATION Bulletin No.: 02-08-42-001D Date: June 21, 2010 Subject: Headlamp Lens Overheating When Covered and Chemical Damage to Exterior Polycarbonate Headlamp Lenses Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and to revise the warning statements. Please discard Corporate Bulletin Number 02-08-42-001C (Section 08 - Body and Accessories). The bulletin is being issued to make dealers and customers aware of chemical damage that may be caused to exterior polycarbonate headlamp lenses. Most late model vehicles have these types of headlamp lenses. This material is used because of its temperature and high impact resistance. A variety of chemicals can cause crazing or cracking of the headlamp lens. Headlamp lenses are very sensitive. Care should be exercised to avoid contact with all exterior headlamp lenses when treating a vehicle with any type of chemical, such as those recommended for rail dust removal. Rubbing compound, grease tar and oil removers, tire cleaners, cleaner waxes and even car wash soaps in too high a concentration may also attribute to this condition. This could result in the need to replace the entire headlamp housing. Warning Use only lukewarm or cold water, a soft cloth and a car washing soap to clean exterior lamps and lenses. Also, crazing or deformations of the lens may occur if a shop mat or fender cover is draped over the fender and covers a portion or all of the headlamp assembly while the DRL or headlamps are on. This action restricts the amount of heat dissipated by the headlamps. Warning Care should be taken to not cover headlamps with shop mats or fender covers if the vehicle is being serviced with the headlamps or DRL illuminated. Covering an illuminated lamp can cause excessive heat build up and crazing/deformation of the lens may occur. The degradation of the lens can be unnoticeable at first and eventually become hairline cracks in the lens. In extreme cases, it could cause the lens to deform. This damage can also be caused by aftermarket shields that are often tinted in color. Once a heat buildup is generated by the headlamp, a degradation of the headlamp lens begins. This degradation of the lens can be unnoticeable at first and eventually manifest as spider cracks. In more extreme cases, it will begin to melt the lens of the headlamp. Notice Headlamps damaged by chemicals, improper cleaning, or overheating due to being covered are not covered under the new vehicle warranty. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams Headlamp Switch: Diagrams Headlamp Switch Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 16425 Headlamp Switch Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 16426 Headlamp Switch: Service and Repair HEADLAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Unsnap the switch from the housing. 3. Disconnect the electrical connectors. 4. Remove the switch. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 16427 1. Connect the electrical connectors. 2. Install the headlamp switch by snapping the headlamps switch into place. 3. Install the bezel to the instrument panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations Horn Switch: Locations Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 16432 Steering Wheel And Column Sub-System Components Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 16433 Steering Wheel and Column Sub-System Components Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 16434 Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 16435 Horn Switch: Service and Repair Horn Switch Replacement Removal Procedure 1. Caution: Refer to Servicing the SIR System Caution in Cautions and Notices. Disable the SIR system. 2. Remove the inflatable restraint steering wheel module. 3. Remove the horn plunger from the steering column by pressing inward to the stop and rotating the horn plunger 90 degrees. 4. Disconnect the captured screws (1,4) to the horn contact plate (2) from the steering wheel (3). 5. Remove the horn switch (2) from the steering wheel (3). Installation Procedure 1. Install the horn switch (2) to the steering wheel (3). 2. Notice: Refer to Fastener Notice in Service Precautions. Connect the captured screws (1,4) from the horn contact plate (2) to the steering wheel (3). ^ Tighten the screws to 5.5 Nm (50 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 16436 3. Install the horn plunger to the steering column. 4. Install the inflator module. 5. Enable the SIR system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Connector Views License Plate Lamp: Connector Views License Lamp - Left Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Connector Views > Page 16441 License Lamp - Right Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 16442 License Plate Lamp: Service and Repair LICENSE LAMP REPLACEMENT (PICKUP W/O BUMPER) REMOVAL PROCEDURE 1. Ensure the headlamp switch is in the OFF position. 2. Remove the lens from the lamp assembly (2). 3. Remove the bulb. INSTALLATION PROCEDURE 1. Install the bulb. 2. Install the lens to the lamp assembly (2). 3. Install the wiring (3) to the back of the lens assembly. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams Courtesy/Reading Lamp - Rear (Crew Cab With RPO Code YE9) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Page 16446 Map Light: Description and Operation READING LAMPS The inadvertent power supply voltage circuit of the BCM provides battery positive voltage to the reading lamps. The reading lamps and switch are integral to the courtesy/reading lamp assembly. When the switch is closed, voltage is supplied and the lamp illuminates. In the event that any of these lamps were to remain illuminated for a period of more than 10 minutes with the ignition switch in the OFF position, the BCM will deactivate the inadvertent power supply voltage circuit to prevent a total battery discharge condition. Ground is provided to the reading lamps at G203. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Marker Lamp Bulb Replacement - Roof (Outer) Marker Lamp Bulb: Service and Repair Marker Lamp Bulb Replacement - Roof (Outer) MARKER LAMP BULB REPLACEMENT - ROOF (OUTER) REMOVAL PROCEDURE 1. Remove the screws from the roof marker lamp lens. 2. Remove the roof marker lamp lens. 3. Remove the bulb. INSTALLATION PROCEDURE 1. In order to install the bulb, push in the bulb until the bulb is seated. 2. Install the roof marker lamp lens. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws to the roof marker lamp lens. Tighten Tighten the screws to 1.9 N.m (17 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Marker Lamp Bulb Replacement - Roof (Outer) > Page 16452 Marker Lamp Bulb: Service and Repair Marker Lamp Bulb Replacement - Roof (Center) MARKER LAMP BULB REPLACEMENT - ROOF (CENTER) REMOVAL PROCEDURE 1. Remove the screws from the roof marker lamp lens. 2. Remove the roof marker lamp lens. 3. Remove the bulb. INSTALLATION PROCEDURE 1. In order to install the bulb, push in the bulb until the bulb is seated. 2. Install the roof marker lamp lens. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws to the roof marker lamp lens. Tighten Tighten the screws to 1.9 N.m (17 lb ft). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Parking Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 16457 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Connector Views Parking Lamp: Connector Views Park/Turn Signal Lamp - LF Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Connector Views > Page 16460 Park/Turn Signal Lamp - RF Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Page 16461 Parking Lamp: Description and Operation PARK, TAIL AND MARKER LAMPS The park, tail and marker lamps, including the license lamps, are turned on when the headlamp switch is placed in the PARK or HEAD position or anytime the headlights are requested. The underhood fuse block supplies battery positive voltage to both the park lamp relay switch contacts and the park lamp coil circuit. The body control module (BCM) provides a ground or control circuit to the park lamp relay coil circuit. When the park lamps are turned on the BCM energizes the park lamp relay. Current flow is from the park lamp relay to the FR PRK 10-amp fuse, RR PRK 10-amp fuse, LR PRK 10-amp fuse, and the TRL PRK 10-amp fuse, and to their respective park and marker lamps. The front park and marker lamps are grounded at G100. The rear park and marker lamps are grounded at G401. The license lamps are grounded at G410. If the headlight switch is left in the ON position, the inadvertent power control feature will turn off the park, tail and marker lamps approximately 10 minutes after the ignition switch is turned to the OFF position. If the driver places the headlight switch in the ON position after the ignition switch has been turned OFF, or if the ignition switch is in the ACCY position, the park, tail and marker lamps will remain ON until turned OFF or the battery runs dead. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Page 16462 Parking Lamp: Service and Repair PARK/TURN SIGNAL LAMP REPLACEMENT (OLD STYLE) REMOVAL PROCEDURE 1. Ensure the headlamp switch is in the OFF position. 2. Remove the headlamp. 3. Remove the park/turn signal lamp assembly by pushing on the inboard retainer clip. 4. Disconnect the electrical connector from the assembly. INSTALLATION PROCEDURE 1. Install the electrical connector to the park/turn signal lamp assembly. 2. Install the lamp assembly. 3. Install the headlamp. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Exterior Lighting Relay > Component Information > Diagrams Roof Beacon Relay (With RPO Code 5X7, 5G4, TRW, Or 5Y0) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: Customer Interest Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 16476 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 16477 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 16483 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Lighting Module: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 16484 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ambient Light Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 16489 Ambient Light Sensor: Diagrams Ambient Light Sensor Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 16490 Ambient Light Sensor (With RPO Code CJ3) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 16491 Ambient Light Sensor: Service and Repair AMBIENT LIGHT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel top cover. 2. Disconnect the electrical connector (1) to the ambient light sensor on the underside of the IP top cover. 3. Turn the ambient light sensor 1/4 turn and remove it from the IP top cover. INSTALLATION PROCEDURE 1. Install the ambient light sensor to the underside of the IP top cover, turning it 1/4 turn to secure it in place. 2. Connect the electrical connector (1) to the ambient light sensor on the underside of the IP top cover. 3. Install the instrument panel top cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams Backup Lamp - Switch (Manual Trans) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > NV 3500 Backup Lamp Switch: Service and Repair NV 3500 Backup Lamp Switch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the backup lamp switch electrical connector (3). 3. Remove the backup lamp switch. Installation Procedure 1. Notice: Refer to Fastener Notice in Service Precautions. Important: The backup lamp switch has pre-applied thread sealant on the threads. Install the backup lamp switch. ^ Tighten the switch to 37 Nm (27 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > NV 3500 > Page 16497 2. Connect the backup lamp switch electrical connector (3). 3. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > NV 3500 > Page 16498 Backup Lamp Switch: Service and Repair NV 4500 Backup Lamp Switch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the backup lamp switch electrical connector (1). 3. Remove the backup lamp switch and seal. Installation Procedure 1. Ensure the seal is installed on the switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the backup lamp switch. ^ Tighten the switch to 28 Nm (21 ft. lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > NV 3500 > Page 16499 3. Connect the backup lamp switch electrical connector (1). 4. Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > NV 3500 > Page 16500 Backup Lamp Switch: Service and Repair ZF S6-650 Backup Lamp Switch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. If equipped with a 6.6L engine, disconnect the backup lamp switch electrical connector (3). 2. If equipped with a 8.1L engine, disconnect the backup lamp switch electrical connector (4). 3. Remove the backup lamp switch. Installation Procedure Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > NV 3500 > Page 16501 1. Notice: Refer to Fastener Notice in Service Precautions. Install the backup lamp switch. ^ Tighten the switch to 20 Nm (15 ft. lbs.). 2. If equipped with a 8.1L engine, connect the backup lamp switch electrical connector (4). 3. If equipped with a 6.6L engine, connect the backup lamp switch electrical connector (3). Lower the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations ABS Component Views Stoplamp Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 16505 Brake Light Switch: Diagrams Stop Lamp Switch Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 16506 Stop Lamp Switch Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 16507 Brake Light Switch: Service and Repair STOP LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the stop lamp switch (2). 2. Remove the pushrod retaining clip (4). 3. Remove the stop lamp switch (2). INSTALLATION PROCEDURE 1. Install the stop lamp switch (2). 2. Install the pushrod retaining clip (4). 3. Connect the electrical connector to the stop lamp switch (2). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Locations Instrument Panel Switches-LH Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Cargo Lamp Switch > Component Information > Locations > Page 16511 Cargo Lamp Switch: Service and Repair LAMP SWITCH ASSEMBLY REPLACEMENT - FRONT FOG LAMP AND CARGO LAMP REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Remove the fog lamp switch and cargo switch from the housing. 3. Disconnect the electrical connector(s) from the fog lamp switch. 4. Remove the fog lamp and cargo lamp switch from the housing. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the fog lamp and cargo lamp switch. 2. Install the fog lamp switch into the housing. 3. Install the IP trim bezel to the instrument panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Combination Switch: Locations Steering Wheel and Column Sub-System Components Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 16515 Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 16516 Steering Wheel And Column Sub-System Components Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 16517 Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 16518 Combination Switch: Diagrams Multifunction Accessory Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 16519 Turn Signal Multifunction Switch - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 16520 Turn Signal Multifunction Switch - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 16521 Turn Signal Multifunction Switch - C3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 16522 Turn Signal Multifunction Switch - C4 (With RPO Code K34) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Driver C2 Door Latch Assembly (Door Jamb Switch) - Driver C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16527 Door Latch Assembly (Door Jamb Switch) - Driver - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16528 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - Front Passenger C2 Door Latch Assembly (Door Jamb Switch) - Front Passenger C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16529 Door Latch Assembly (Door Jamb Switch) - Front Passenger - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16530 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - LR C2 (Crew Cab Only) Door Latch Assembly (Door Jamb Switch) - LR C2 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16531 Door Latch Assembly (Door Jamb Switch) - LR - C2 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16532 Door Switch: Diagrams Door Latch Assembly (Door Jamb Switch) - RR C2 (Crew Cab Only) Door Latch Assembly (Door Jamb Switch) - RR C2 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Latch Assembly (Door Jamb Switch) - Driver C2 > Page 16533 Door Latch Assembly (Door Jamb Switch) - RR - C2 (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 16534 Door Switch: Description and Operation DOOR LATCH (DOOR JAMB) SWITCHES The theft deterrent system uses the door key switch as one method in order to activate the alarm. If the BCM detects any door opening before the BCM receives a disarm input, the alarm mode activates. DOOR KEY SWITCH The BCM monitors the door key switches in order to disarm the CTD system. When the lock cylinder turns in order to unlock the door, the switch grounds the disarm input to the BCM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations Fog/Driving Lamp Switch: Locations Instrument Panel Switches-LH Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 16538 Accessory Switch Housing Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 16539 Fog Lamp Switch Rear (With RPO Code T79) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Lamp Switch Assembly Replacement-Front Fog Lamp and Cargo Lamp Fog/Driving Lamp Switch: Service and Repair Lamp Switch Assembly Replacement-Front Fog Lamp and Cargo Lamp LAMP SWITCH ASSEMBLY REPLACEMENT - FRONT FOG LAMP AND CARGO LAMP REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Remove the fog lamp switch and cargo switch from the housing. 3. Disconnect the electrical connector(s) from the fog lamp switch. 4. Remove the fog lamp and cargo lamp switch from the housing. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the fog lamp and cargo lamp switch. 2. Install the fog lamp switch into the housing. 3. Install the IP trim bezel to the instrument panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Lamp Switch Assembly Replacement-Front Fog Lamp and Cargo Lamp > Page 16542 Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement - Rear FOG LAMP SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the instrument panel bezel. 2. Pull out the accessary switch housing. 3. Disconnect the electrical connectors. 4. Remove the fog lamp switch from the accessary switch housing. INSTALLATION PROCEDURE 1. Install the fog lamp switch into accessary switch housing. 2. Connect the electrical connectors. 3. Install the accessary switch housing. 4. Install the instrument panel bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair INSTRUMENT PANEL (I/P) COMPARTMENT LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Lower the instrument panel storage compartment door by pressing in the tab. 2. With one hand holding the plunger of the switch, use a small screw driver to push in the tabs on each side while pulling outwards. 3. Pull the switch assembly from the I/P. 4. Disconnect the electrical connector. 5. Remove the bulb (1). INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair > Page 16546 1. Install the bulb (1) into the socket. 2. Connect the electrical connector. 3. Install the switch until the tabs (1) click in place. 4. Close the compartment door. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Hazard Warning Switch: Locations Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 16550 Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Alignment Switch > Component Information > Diagrams Headlamp Leveling Switch (Export) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Alignment Switch > Component Information > Diagrams > Page 16554 Headlamp Alignment Switch: Service and Repair HEADLAMP LEVELING SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel bezel. 2. Pull out the accessary switch housing. 3. Disconnect the electrical connectors. 4. Remove the head lamp leveling switch from the accessary switch housing. INSTALLATION PROCEDURE 1. Install the head lamp leveling switch into accessary switch housing. 2. Connect the electrical connectors. 3. Install the accessary switch housing. 4. Install the instrument panel bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Instrument Panel Switches-LH Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams Headlamp Switch: Diagrams Headlamp Switch Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 16561 Headlamp Switch Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 16562 Headlamp Switch: Service and Repair HEADLAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument cluster bezel. 2. Unsnap the switch from the housing. 3. Disconnect the electrical connectors. 4. Remove the switch. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 16563 1. Connect the electrical connectors. 2. Install the headlamp switch by snapping the headlamps switch into place. 3. Install the bezel to the instrument panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Horn Switch: Locations Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 16567 Steering Wheel And Column Sub-System Components Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 16568 Steering Wheel and Column Sub-System Components Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 16569 Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 16570 Horn Switch: Service and Repair Horn Switch Replacement Removal Procedure 1. Caution: Refer to Servicing the SIR System Caution in Cautions and Notices. Disable the SIR system. 2. Remove the inflatable restraint steering wheel module. 3. Remove the horn plunger from the steering column by pressing inward to the stop and rotating the horn plunger 90 degrees. 4. Disconnect the captured screws (1,4) to the horn contact plate (2) from the steering wheel (3). 5. Remove the horn switch (2) from the steering wheel (3). Installation Procedure 1. Install the horn switch (2) to the steering wheel (3). 2. Notice: Refer to Fastener Notice in Service Precautions. Connect the captured screws (1,4) from the horn contact plate (2) to the steering wheel (3). ^ Tighten the screws to 5.5 Nm (50 inch lbs.). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 16571 3. Install the horn plunger to the steering column. 4. Install the inflator module. 5. Enable the SIR system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 16575 Steering Wheel And Column Sub-System Components Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 16576 Steering Wheel and Column Sub-System Components Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 16577 Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 16578 Turn Signal Switch: Diagrams Turn Signal Multifunction Switch - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 16579 Turn Signal Multifunction Switch - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 16580 Turn Signal Multifunction Switch - C3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 16581 Turn Signal Multifunction Switch - C4 (With RPO Code K34) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Tail Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 16586 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Connector Views Tail Lamp: Connector Views Tail/Stop Lamp - Left Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Connector Views > Page 16589 Tail/Stop Lamp - Right Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 16590 Tail Lamp: Description and Operation PARK, TAIL AND MARKER LAMPS The park, tail and marker lamps, including the license lamps, are turned on when the headlamp switch is placed in the PARK or HEAD position or anytime the headlights are requested. The underhood fuse block supplies battery positive voltage to both the park lamp relay switch contacts and the park lamp coil circuit. The body control module (BCM) provides a ground or control circuit to the park lamp relay coil circuit. When the park lamps are turned on the BCM energizes the park lamp relay. Current flow is from the park lamp relay to the FR PRK 10-amp fuse, RR PRK 10-amp fuse, LR PRK 10-amp fuse, and the TRL PRK 10-amp fuse, and to their respective park and marker lamps. The front park and marker lamps are grounded at G100. The rear park and marker lamps are grounded at G401. The license lamps are grounded at G410. If the headlight switch is left in the ON position, the inadvertent power control feature will turn off the park, tail and marker lamps approximately 10 minutes after the ignition switch is turned to the OFF position. If the driver places the headlight switch in the ON position after the ignition switch has been turned OFF, or if the ignition switch is in the ACCY position, the park, tail and marker lamps will remain ON until turned OFF or the battery runs dead. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 16591 Tail Lamp: Service and Repair TAIL/TURN SIGNAL LAMP REPLACEMENT (EXCEPT STEPSIDE) REMOVAL PROCEDURE 1. Ensure that the headlamp switch is in the OFF position. 2. Lower the end gate. 3. Remove the 2 screws retaining the tail/turn signal lamp assembly to the body. 4. Identify the bulb in need of replacement. - The top bulb is a parking lamp and stop lamp - The center bulb is a turn indicator lamp - The lower bulb is a backup lamp 5. Turn the socket assembly. 6. Remove the socket assembly from the housing. INSTALLATION PROCEDURE 1. Turn the socket. 2. Lock the socket in place. 3. Install the tail/turn signal lamp assembly to the vehicle with the 2 screws. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 16592 4. Close the endgate. 5. Inspect the operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: Customer Interest Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 16601 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 16602 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON Trailer Lighting Module: All Technical Service Bulletins Electrical - Trailer Brakes Apply With Headlamps ON Bulletin No.: 02-05-22-004C Date: April 05, 2005 TECHNICAL Subject: Trailer Brakes Applied When Headlights/Park Lamps Are On, Brake Controller Illumination (Modify Brake Controller Wiring Harness) Models: 2002-2005 Cadillac Escalade, Escalade EXT 1999-2005 Chevrolet Silverado 2000-2005 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Avalanche 1999-2005 GMC Sierra 2000-2005 GMC Yukon, Yukon XL 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 02-05-22-004B (Section 05 - Brakes). Condition Some customers may comment that when the headlamps or park lamps are on, the brakes on the trailer are always applied, or that the back lighting for the trailer brake controller only illuminates when the brakes are applied. Cause The cause of this condition may be due to wiring changes within the vehicle electrical system for the 2003 model year. Correction Inspect the brake controller wiring harness jumper that is plugged into the vehicle relay block-body. The relay block-body is located under the left side of the instrument panel near the left kick panel, behind a plastic cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 16608 The 1999 though early 2003 wiring harness jumper that plugs into the relay block will have a reddish/brown 6-way connector and a tag with the last four digits of the wiring harness part number. Second design 2003-05 may have a white plastic connector with part number 5418 as well. ^ The 1999 jumper is/was P/N 12171982 with a pink/purple tag identifier of 1982. This number has been superseded to 15366255, with a pink/purple tag identifier of 6255. ^ The 2000 jumper harness is P/N 15366255. The pink/purple tag identifier is 6255. ^ The 2001-2002 jumper is P/N 15086884. The orange tag identifier is 6884. ^ The 2003-05 jumper is P/N 15085418. The orange tag identifier is 5418. When transferring the brake controller with the wiring jumper attached from a 2001-2002 vehicle to a 2003-05 vehicle, a change to the jumper harness connector must be performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-05-22-004C > Apr > 05 > Electrical - Trailer Brakes Apply With Headlamps ON > Page 16609 The information shown is for the 1999-2002 wiring harnesses and for the 2003-05 wiring harness. To modify a 12171982, 15366255 or 15086884 harness for use in a 2003-05 vehicle, switch the wires in cavities "A" and "D". To modify a 15085418 harness for use in a 1999-2002 vehicle (see model list at the front of this bulletin for applicable models), switch the wires in cavities "A" and "D". Warranty Information When the correct wiring harness P/N is matched to the specific model year of the vehicle, everything works properly. Therefore, conversion of an incorrect wiring jumper to match the vehicle would not be considered a warrantable repair. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Lighting Module: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough Hose/Line HVAC: All Technical Service Bulletins A/C - Doesn't Blow Cold Enough Bulletin No.: 02-01-38-007C Date: July 27, 2004 TECHNICAL Subject: Poor A/C Performance - A/C Will Not Blow Cold Enough (Perform A/C System Checks, Replace Accumulator if Necessary) Models: 2002-2004 Chevrolet Silverado 2002-2004 GMC Sierra with 6.6L Diesel Engine (VINs 1, 2 - RPOs LB7, LLY) and Denso A/C Compressor Supercede: This bulletin is being revised to add part numbers for the hose, bracket and insulator to the Parts Information. Please discard Corporate Bulletin Number 02-01-38-007B (Section 01 - HVAC). Condition Some customers may comment on less than desirable A/C performance, especially when the ambient temperature is above 32°C (90°F). Correction Perform the following A/C system checks and replace the accumulator with P/N 89018601, if necessary. This new accumulator requires the accumulator bracket, the accumulator insulator and the A/C suction hose to be replaced also. ^ Check for A/C system leaks. ^ Check the A/C system for proper refrigerant charge. This requires recovering the refrigerant to determine charge in system. Refer to Refrigerant Recovery and Recharging in the HVAC sub-section of the Service Manual. ^ If no leaks were found and the A/C system is charged to specification, replace the accumulator using the procedure listed below. If normal diagnostics do not lead to a correction, then perform the following A/C system checks. 1. Re-calibrate the actuators. 2. Inspect the lower A/C condenser deflector for proper installation. The deflector should be positioned at the lower part of the condenser and extend forward into the top of the front bumper and below the two fresh air intake holes. 3. Check the engine cooling fan clutch for proper operation. 4. If the vehicle is equipped with a front license plate, inspect for proper installation. If the license plate bracket is installed upside down, it will block part of the two fresh air intake holes in the bumper. When the license plate bracket is installed correctly, the writing on the back of the bracket will be upside down. Inspect for material between the radiator and condenser. Remove the top plate to confirm that there is no restriction. A radiator front filled with material will decrease condenser performance. 5. Some improvements have been found by lowering the A/C charge from 0.82 kg (1.8 lbs) to 0.73 kg (1.6 lbs). 6. Check the low pressure cycling switch for proper operation. The low pressure switch opens at 172-234 kPa (25-34 psi) which stops compressor operation and closes when the low side pressure reaches 276-310 kPa (40-45 psi). This enables the compressor to turn back on. Important: Compressor clutch engagement cannot be used to determine the status of the low pressure switch. The low pressure switch is one of several inputs to the HVAC control module for A/C request authorization. A/C request is one of several inputs to the powertrain control module (PCM) that control A/C compressor clutch engagement. Using a scan tool to monitor low pressure switch status while monitoring the low side pressure with the ACR 2000 at the service port and watch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Lighting Module: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough > Page 16615 the pressure at which the switch opens/closes is imperative to successfully diagnosing the switch. 7. If the A/C performance has not improved after performing the above steps, replace the accumulator with P/N 89018601, using the procedure listed below. This new accumulator also requires the accumulator bracket, accumulator insulator and A/C suction hose to be replaced. Accumulator Replacement 1. Remove the suction hose mounting bolt from the A/C compressor. 2. Remove the suction hose from the compressor. 3. Remove the suction hose nut from the accumulator. 4. Remove the suction hose from the accumulator. 5. Remove the evaporator tube nut from the evaporator. 6. Remove the evaporator tube from the evaporator. 7. Disconnect the electrical connector from the A/C low pressure switch. 8. Remove the nut from the evaporator fitting. 9. Remove the accumulator bracket nut from the retaining stud. 10. Remove the accumulator. 11. Remove the retaining bracket bolt. This bolt must be reused for the new bracket. 12. Remove the insulator. One half of the insulator must be reused. 13. Install the new insulator and one half of the old insulator onto the new accumulator. 14. Install the new retaining bracket and bolt to the accumulator. Do not tighten at this time. 15. Add the PAG oil directly into the new accumulator that was removed during the recovery process plus an additional 90 ml (3 oz). 16. Install the new accumulator. 17. Install the accumulator bracket nut. Tighten Tighten the nut to 9 N.m (80 lb in). 18. Tighten the retaining bracket bolt. Tighten Tighten the nut to 10 N.m (89 lb in). 19. Install the nut to the evaporator fitting. Tighten Tighten the nut to 16 N.m (12 lb ft). 20. Install the evaporator tube to the evaporator. 21. Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N.m (12 lb ft). 22. Install the new suction hose to the accumulator. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Lighting Module: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough > Page 16616 23. Install the suction hose nut to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft). 24. Connect the electrical connector to the A/C low pressure switch. 25. Install the new suction hose to the compressor. 26. Install the suction hose mounting bolt to the A/C compressor. Tighten Tighten the bolt to 16 N.m (12 lb ft). Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Lighting Module: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough > Page 16622 the pressure at which the switch opens/closes is imperative to successfully diagnosing the switch. 7. If the A/C performance has not improved after performing the above steps, replace the accumulator with P/N 89018601, using the procedure listed below. This new accumulator also requires the accumulator bracket, accumulator insulator and A/C suction hose to be replaced. Accumulator Replacement 1. Remove the suction hose mounting bolt from the A/C compressor. 2. Remove the suction hose from the compressor. 3. Remove the suction hose nut from the accumulator. 4. Remove the suction hose from the accumulator. 5. Remove the evaporator tube nut from the evaporator. 6. Remove the evaporator tube from the evaporator. 7. Disconnect the electrical connector from the A/C low pressure switch. 8. Remove the nut from the evaporator fitting. 9. Remove the accumulator bracket nut from the retaining stud. 10. Remove the accumulator. 11. Remove the retaining bracket bolt. This bolt must be reused for the new bracket. 12. Remove the insulator. One half of the insulator must be reused. 13. Install the new insulator and one half of the old insulator onto the new accumulator. 14. Install the new retaining bracket and bolt to the accumulator. Do not tighten at this time. 15. Add the PAG oil directly into the new accumulator that was removed during the recovery process plus an additional 90 ml (3 oz). 16. Install the new accumulator. 17. Install the accumulator bracket nut. Tighten Tighten the nut to 9 N.m (80 lb in). 18. Tighten the retaining bracket bolt. Tighten Tighten the nut to 10 N.m (89 lb in). 19. Install the nut to the evaporator fitting. Tighten Tighten the nut to 16 N.m (12 lb ft). 20. Install the evaporator tube to the evaporator. 21. Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N.m (12 lb ft). 22. Install the new suction hose to the accumulator. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Lighting Module: > 02-01-38-007C > Jul > 04 > A/C - Doesn't Blow Cold Enough > Page 16623 23. Install the suction hose nut to the accumulator. Tighten Tighten the nut to 16 N.m (12 lb ft). 24. Connect the electrical connector to the A/C low pressure switch. 25. Install the new suction hose to the compressor. 26. Install the suction hose mounting bolt to the A/C compressor. Tighten Tighten the bolt to 16 N.m (12 lb ft). Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations Combination Switch: Locations Steering Wheel and Column Sub-System Components Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 16628 Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 16629 Steering Wheel And Column Sub-System Components Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 16630 Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 16631 Combination Switch: Diagrams Multifunction Accessory Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 16632 Turn Signal Multifunction Switch - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 16633 Turn Signal Multifunction Switch - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 16634 Turn Signal Multifunction Switch - C3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 16635 Turn Signal Multifunction Switch - C4 (With RPO Code K34) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Service and Repair Turn Signal Flasher: Service and Repair HAZARD AND TURN SIGNAL FLASHER REPLACEMENT REMOVAL PROCEDURE 1. Remove the knee bolster. 2. On the back side of the fuse block release the retainer while pulling the flasher (1) outwards. 3. Remove the flasher (1) from the fuse block. INSTALLATION PROCEDURE 1. Install the flasher (1) to the fuse block until the retainer clicks into place. 2. Install the knee bolster. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Turn Signal Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 16643 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 16644 Turn Signal Lamp: Diagrams Park/Turn Signal Lamp - LF Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 16645 Park/Turn Signal Lamp - RF Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 16646 Turn Signal Lamp: Description and Operation TURN SIGNAL/HAZARD LAMPS The IGN E 10-amp fuse in the underhood fuse block supplies battery positive voltage to the turn signal/hazard switch assembly. The FLASH 25-amp fuse in the instrument panel (I/P) fuse block supplies battery positive voltage to the turn signal/flasher module and ground is supplied at G200. When the turn signal switch is placed in either the LEFT or RIGHT position, a voltage signal is completed from the turn signal switch to the turn sign/flasher module. When the hazard flasher switch is activated, a ground signal is completed from the turn signal/hazard switch to the turn sign/flasher module. The turn sign/flasher module then sends an on-off voltage signal through the LT TRLR, RT TRLR, LT TURN or RT TURN 10-amp fuses in the I/P fuse block to the appropriate turn signal or to all 4 fuses for hazard operation. The instrument panel cluster (IPC) indicators receive voltage from the LT TURN and RT TURN fuses as well as the driver door module (DDM)/passenger door module (PDM) for the mirror turn signals. The DDM/PDM has no function or control of the mirror turn signals other that a pass through connection for the circuits. The audio chime is also activated when the turn signals are ON. When the hazard switch is pressed, all turn signal lamps will flash including both IPC turn indicators. The front turn signals are grounded at G100. The rear turn signals are grounded at G401. The Mirror turn signals are grounded by the DDM/PDM. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Service and Repair > Park/Turn Signal Lamp Replacement (Old Style) Turn Signal Lamp: Service and Repair Park/Turn Signal Lamp Replacement (Old Style) PARK/TURN SIGNAL LAMP REPLACEMENT (OLD STYLE) REMOVAL PROCEDURE 1. Ensure the headlamp switch is in the OFF position. 2. Remove the headlamp. 3. Remove the park/turn signal lamp assembly by pushing on the inboard retainer clip. 4. Disconnect the electrical connector from the assembly. INSTALLATION PROCEDURE 1. Install the electrical connector to the park/turn signal lamp assembly. 2. Install the lamp assembly. 3. Install the headlamp. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Service and Repair > Park/Turn Signal Lamp Replacement (Old Style) > Page 16649 Turn Signal Lamp: Service and Repair Tail/Turn Signal Lamp Replacement (Except Stepside) TAIL/TURN SIGNAL LAMP REPLACEMENT (EXCEPT STEPSIDE) REMOVAL PROCEDURE 1. Ensure that the headlamp switch is in the OFF position. 2. Lower the end gate. 3. Remove the 2 screws retaining the tail/turn signal lamp assembly to the body. 4. Identify the bulb in need of replacement. - The top bulb is a parking lamp and stop lamp - The center bulb is a turn indicator lamp - The lower bulb is a backup lamp 5. Turn the socket assembly. 6. Remove the socket assembly from the housing. INSTALLATION PROCEDURE 1. Turn the socket. 2. Lock the socket in place. 3. Install the tail/turn signal lamp assembly to the vehicle with the 2 screws. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Service and Repair > Park/Turn Signal Lamp Replacement (Old Style) > Page 16650 4. Close the endgate. 5. Inspect the operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 16654 Steering Wheel And Column Sub-System Components Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 16655 Steering Wheel and Column Sub-System Components Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 16656 Upper Steering Column Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 16657 Turn Signal Switch: Diagrams Turn Signal Multifunction Switch - C1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 16658 Turn Signal Multifunction Switch - C2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 16659 Turn Signal Multifunction Switch - C3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 16660 Turn Signal Multifunction Switch - C4 (With RPO Code K34) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Service and Repair Underhood Lamp: Service and Repair UNDERHOOD LAMP REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector. 2. Squeeze the lower tab. Remove the underhood lamp from the hood. 3. Remove the lens cover. Use a small flat bladed tool in order to pry the cover off. 4. Remove the bulb from the socket. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Service and Repair > Page 16664 1. Install the bulb to the socket. 2. Install the lens cover. 3. Install the underhood lamp to the hood. 4. Connect the in-line electrical connector. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-42-002A > Jan > 07 > Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. Vanity Lamp: Customer Interest Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. Bulletin No.: 06-08-42-002A Date: January 23, 2007 TECHNICAL Subject: Sunshade (Visor) Vanity Mirror Bulb Inoperative (Replace Vanity Mirror Bulb Only) Models: 2005-2007 Buick Allure (Canada Only), LaCrosse 2005-2007 Cadillac STS 2001-2005 Chevrolet Impala, Monte Carlo 2001-2006 Chevrolet Silverado Crew Cab, Suburban, Tahoe 2001-2006 GMC Sierra Crew Cab, Yukon, Yukon XL 2004-2005 Pontiac Grand Prix 2006-2007 HUMMER H3 Supercede: This bulletin is being updated to add the 2007 model year. Please discard Corporate Bulletin Number 06-08-42-002 (Section 08 - Body & Accessories). Condition Some customers may comment that a sunshade (visor) vanity mirror bulb is inoperative. Cause This condition may be caused by an inoperative bulb. Correction Do NOT replace the entire sunshade (visor) assembly. Replace the sunshade (visor) vanity mirror bulb with P/N 9442395 if repairing one of the affected models covered for an inoperative vanity mirror bulb. Refer to Vanity Mirror Lamp Replacement in SI. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-42-002A > Jan > 07 > Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. > Page 16673 The vanity mirror bulb can be accessed by removing the lens. Place a flat-bladed tool in the notches and gently pry out the lens. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-42-002A > Jan > 07 > Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. Vanity Lamp: All Technical Service Bulletins Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. Bulletin No.: 06-08-42-002A Date: January 23, 2007 TECHNICAL Subject: Sunshade (Visor) Vanity Mirror Bulb Inoperative (Replace Vanity Mirror Bulb Only) Models: 2005-2007 Buick Allure (Canada Only), LaCrosse 2005-2007 Cadillac STS 2001-2005 Chevrolet Impala, Monte Carlo 2001-2006 Chevrolet Silverado Crew Cab, Suburban, Tahoe 2001-2006 GMC Sierra Crew Cab, Yukon, Yukon XL 2004-2005 Pontiac Grand Prix 2006-2007 HUMMER H3 Supercede: This bulletin is being updated to add the 2007 model year. Please discard Corporate Bulletin Number 06-08-42-002 (Section 08 - Body & Accessories). Condition Some customers may comment that a sunshade (visor) vanity mirror bulb is inoperative. Cause This condition may be caused by an inoperative bulb. Correction Do NOT replace the entire sunshade (visor) assembly. Replace the sunshade (visor) vanity mirror bulb with P/N 9442395 if repairing one of the affected models covered for an inoperative vanity mirror bulb. Refer to Vanity Mirror Lamp Replacement in SI. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-42-002A > Jan > 07 > Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. > Page 16679 The vanity mirror bulb can be accessed by removing the lens. Place a flat-bladed tool in the notches and gently pry out the lens. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vanity Lamp: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel Steering Column Bearing: All Technical Service Bulletins Steering - Underhood Clunk Heard/Felt in Steering Wheel TECHNICAL Bulletin No.: 00-02-35-003N Date: March 26 2008 Subject: Clunking Noise Under Hood and Can Be Felt in Steering Wheel and/or Steering Column (Replace Upper Intermediate Steering Shaft [I-Shaft] Assembly) Models: 2002-2006 Cadillac Escalade Models 1999-2007 Chevrolet Silverado Models (Classic) 2000-2006 Chevrolet Suburban, Tahoe Models 2002-2006 Chevrolet Avalanche 1999-2007 GMC Sierra Models (Classic) 2000-2006 GMC Yukon, Yukon XL Models 2003-2006 HUMMER H2 Attention: This Service Bulletin DOES NOT include Mid-Size Utilities such as Buick Rainier, Chevrolet TrailBlazer Models, GMC Envoy Models or Oldsmobile Bravada. Refer to Service Bulletin 02-02-35-006A or newer for Mid-Size Utilities. Supercede: This bulletin is being revised to add diagnostic information (refer to Diagnostic Tips) to check the lower steering column bearing as a potential source of the noise. Please discard Corporate Bulletin Number 00-02-35-003M (Section 02-Steering). Condition Some customers may comment on a clunk-type noise coming from under the hood that also can be felt in the steering wheel. These conditions may be more noticeable when turning at low speeds on rough road surfaces. Diagnostic Tips Use the information below to help diagnose the source of the noise. ^ The lower steering column bearing may create the same noise as the intermediate shaft. Before replacing the I-shaft, verify the noise isn't being caused by movement from the lower steering column bearing. Check the bearing for movement by pushing up and down on the I-shaft where it attaches to the steering column. ^ Frame Snap and/or Popping Type Noise - A frame snap or popping type noise can be duplicated on rough or smooth road surfaces with steering wheel input to the left or the right. This type of noise can be HEARD and is typically louder with the windows rolled down. For additional information refer to Corporate Bulletin Number 03-08-61-002F or newer - Snap/Popping Type Noise Coming from Front of Vehicle (Remove Front Crossmember Change Fastener Orientation). ^ Intermediate Shaft Clunk - Intermediate shaft clunk is heard and FELT in the steering wheel and/or steering column area typically while driving on rough road surfaces with steering wheel input. Correction Important: ^ I-shaft P/N 19153614 has been designed to replace previous designed dampened and non-dampened I-shafts. The physical difference in the yoke size will accommodate all vehicles listed in this bulletin. ^ Due to the design of the new I-shaft, it is not possible to lubricate/grease the I-shaft. Replace the steering column upper intermediate shaft with an improved design shaft that will eliminate the clunk noise using the procedure listed below. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vanity Lamp: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 16685 1. Set the front wheels in the straight ahead position. Notice: On the 2002 and later model year vehicles the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil. 2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles. 3. For 2002 and later vehicles install the J 42640 in the steering column lower access hole. 4. From under the hood remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft. 5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft. 6. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the carpet away from the accelerator pedal position (APP) sensor. 2. Remove the two nuts retaining the accelerator pedal to the bulkhead. 3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vanity Lamp: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 16686 7. From inside the vehicle remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection. 8. Remove the upper intermediate steering shaft assembly. 1. From inside the vehicle slide the shaft down and off the steering column. 2. From inside the vehicle slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle. 9. Replace the upper intermediate shaft. 10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft. 11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft. 12. Install the upper bolt and nut. Tighten Tighten the bolt to 47 N.m (35 lb ft). 13. Install the lower bolt and nut. Tighten Tighten the bolt to 50 N.m (37 lb ft). 14. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the accelerator pedals into position on the bulkhead. 2. Install the two retaining nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Reposition the carpet into place. Parts Information Warranty Information For vehicles repaired under warranty use, the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vanity Lamp: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 16687 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vanity Lamp: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 16693 1. Set the front wheels in the straight ahead position. Notice: On the 2002 and later model year vehicles the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil. 2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles. 3. For 2002 and later vehicles install the J 42640 in the steering column lower access hole. 4. From under the hood remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft. 5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft. 6. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the carpet away from the accelerator pedal position (APP) sensor. 2. Remove the two nuts retaining the accelerator pedal to the bulkhead. 3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vanity Lamp: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 16694 7. From inside the vehicle remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection. 8. Remove the upper intermediate steering shaft assembly. 1. From inside the vehicle slide the shaft down and off the steering column. 2. From inside the vehicle slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle. 9. Replace the upper intermediate shaft. 10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft. 11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft. 12. Install the upper bolt and nut. Tighten Tighten the bolt to 47 N.m (35 lb ft). 13. Install the lower bolt and nut. Tighten Tighten the bolt to 50 N.m (37 lb ft). 14. For vehicles equipped with adjustable foot pedals perform the following steps: 1. Reposition the accelerator pedals into position on the bulkhead. 2. Install the two retaining nuts. Tighten Tighten the nuts to 20 N.m (15 lb ft). 3. Reposition the carpet into place. Parts Information Warranty Information For vehicles repaired under warranty use, the table. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vanity Lamp: > 00-02-35-003N > Mar > 08 > Steering - Underhood Clunk Heard/Felt in Steering Wheel > Page 16695 Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Connector Views Vanity Lamp: Connector Views Vanity Mirror Lamp - Left (With RPO Code Y91) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Connector Views > Page 16698 Vanity Mirror Lamp - Right (With RPO Code Y91) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Page 16699 Vanity Lamp: Description and Operation VANITY LAMPS The inadvertent power supply voltage circuit of the BCM provides battery positive voltage to each vanity mirror lamp. When the vanity mirror cover on the sunshade is opened, a switch closes to provide a ground circuit and the vanity lamp illuminates. In the event that any of these lamps were to remain illuminated for a period of more than 10 minutes with the ignition switch in the OFF position, the BCM will deactivate the inadvertent power supply voltage circuit to prevent a total battery discharge condition. Ground is provided to the vanity lamps at G203. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Heated Glass Element: Customer Interest A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 16709 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 16710 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 16711 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Heated Glass Element: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 16717 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 16718 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 16719 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Page 16720 Inside Rearview Mirror Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions Heated Glass Element: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16723 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16724 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16725 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16726 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16727 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16728 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16729 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16730 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16731 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16732 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16733 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16734 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16735 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16736 Heated Glass Element: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16737 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16738 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16739 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16740 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16741 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16742 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16743 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16744 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16745 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16746 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16747 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16748 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16749 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16750 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16751 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16752 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16753 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16754 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16755 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16756 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16757 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16758 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16759 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16760 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16761 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16762 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16763 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16764 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16765 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16766 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16767 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16768 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16769 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16770 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 16771 Heated Glass Element: Electrical Diagrams Defogger Diagram Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Description and Operation > Rear Window Defogger Heated Glass Element: Description and Operation Rear Window Defogger REAR WINDOW DEFOGGER DESCRIPTION AND OPERATION REAR WINDOW DEFOGGER SYSTEM COMPONENTS The rear window defogger system consist of the following components: HVAC control module - Body control module (BCM) - DEFOG relay - Rear window defogger grid REAR WINDOW DEFOGGER OPERATION When you turn the ignition to the ON position, ignition voltage is supplied to the DEFOG relay coil. Battery positive voltage is supplied at all times to the DEFOG relay switched input. When the rear window defogger switch is depressed, the HVAC control module illuminates the rear window defogger indicator and sends a class 2 message to the BCM. The BCM energizes the DEFOG relay by grounding the control circuit of the relay. This allows battery positive voltage from the relay switched input through the switch contacts and out the relay switched output to the rear window defogger. Ground for the rear window defogger is provided by G306 or G390 (crew cab). When you turn ON the ignition and press the rear window defogger switch for the first time, the defogger cycle lasts 10 minutes. Further operation results in 5 minute defogger cycles. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Description and Operation > Rear Window Defogger > Page 16774 Heated Glass Element: Description and Operation Compass Calibration and Variance Procedure COMPASS CALIBRATION AND VARIANCE PROCEDURE COMPASS CALIBRATION Before calibrating the compass, drive the vehicle to an open area that is magnetically clean or free of large metallic objects such as high tension power lines or large steel buildings. Verify there are no magnetized roof antennas, magnets on or hanging from the mirror, or any other magnetized objects on the inside or outside of the vehicle close to the mirror. 1. Start the engine. IMPORTANT: Before calibrating the compass, make sure the mirror has the correct zone number. Refer to Compass Magnetic Variation Adjustment. 2. Press and hold the switch for the compass, which may be depicted as COMP, COMPASS, or on/off (w/UE1) depending on the type of mirror on the vehicle, until the letter "C" or "CAL" is displayed. 3. Drive the vehicle in circles at a speed of less than 8 km/h (5 mph) until the "C" or "CAL" is replaced by a proper vehicle heading. The calibration procedure is now complete. COMPASS MAGNETIC VARIATION ADJUSTMENT Magnetic variation adjustments are required when the compass displays a constant error in heading. Variation is the difference between magnetic north and true north due to geographical location. 1. Locate your current geographic location on the World Magnetic Variation Map. 2. Turn ON the ignition, with the engine OFF. 3. Press and hold the switch for the compass, which may be depicted as COMP, COMPASS, or on/off (w/UE1) depending on the type of mirror on the vehicle, until a zone number appears on the compass display. 4. Depress the switch for the compass to select the desired zone number. 5. Wait 5 seconds. The display will return to a compass heading. The variance procedure is now complete. 6. Calibrate the compass. Refer to Compass Calibration mentioned above. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Heated Glass Element: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Heated Glass Element DIAGNOSTIC STARTING POINT For the inside rearview mirror with the automatic day-night feature, begin the diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Heated Glass Element in order to identify the correct procedure for diagnosing the system and where the procedure is located. See: Symptom Related Diagnostic Procedures For the rear window defogger, begin the diagnosis with the Diagnostic System Check - Defogger. The Diagnostic System Check will provide the following information: - The identification of the control modules which command the system - The ability of the control modules to communicate through the serial data circuit - The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check - Defogger DIAGNOSTIC SYSTEM CHECK - DEFOGGER TEST DESCRIPTION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 16777 Steps 1-3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 16778 Steps 4-7 The numbers below refer to the step numbers on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 4. The Symptom Table will determine the correct diagnostic procedure to use. 5. The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 16779 Heated Glass Element: Symptom Related Diagnostic Procedures A Symptoms SYMPTOMS IMPORTANT: - For the inside rearview mirror with the automatic day-night feature, review the system operation in order to familiarize yourself with the system functions. Refer to Automatic Day-Night Mirror Description and Operation. - For the rear window defogger system, the following steps must be performed before using the symptom tables: 1. Perform the Diagnostic System Check - Defogger before using the symptom tables in order to verify that all of the following are true: - There are no DTCs set. - The control modules can communicate via the serial data link. See: Initial Inspection and Diagnostic Overview/Diagnostic System Check - Defogger 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Rear Window Defogger Description and Operation. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the rear window defogger or the automatic day-night feature of the inside rearview mirror. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Defogger Inoperative - Rear Window - Defogger Grid Lines Diagnosis - Mirrors - Automatic Day-Night Inoperative - Mirrors - Temperature Displays SC or OC - Mirrors - Compass Display Inoperative or Inaccurate Automatic Day/Night Mirror Inoperative - Mirrors MIRRORS - AUTOMATIC DAY-NIGHT INOPERATIVE DIAGNOSTIC AIDS The automatic day-night feature of the inside rearview mirror may not operate properly or become inoperative due to an intermittent short to battery voltage in the backup lighting system. TEST Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 16780 Steps 1-2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 16781 Steps 3-7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 16782 Steps 8-12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 16783 Steps 1-6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 16784 Steps 7-10 Steps 1-4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 16785 Steps 5-10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 16786 Steps 11-15 Temperature Displays SC or OC - Mirrors MIRRORS - TEMPERATURE DISPLAYS SC OR OC Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 16787 Ambient Air Temperature Sensor Resistance The table will be used to measure the resistance of the sensor and compare it with the actual ambient temperature. The mirror's temperature accuracy should be within 5 degrees of the actual temperature. The actual temperature should not be taken from a radio station, a sign displaying the temperature, etc. A temperature measuring tool such as a thermometer should be used. Some temperature measuring tools may be within 5 degrees of the actual temperature. Make sure to consult the manufacturer for the accuracy of the tool. This comparison can make the mirror seem off by 5-10 degrees of the actual temperature when it is not. TEST Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 16788 Steps 1-5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 16789 Steps 6-11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 16790 Steps 12-17 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 16791 Heated Glass Element: Component Tests and General Diagnostics DEFOGGER GRID LINES DIAGNOSIS This test is for reference only. A grid line fault requires the rear window replacement. Refer to Rear Window Replacement (Pickup). 1. Start the engine. 2. Activate the rear window defogger system. 3. Connect a test lamp to a good ground. IMPORTANT: The test lamp brilliance will decrease proportionately to the increased resistance in the grid line as the probe is moved from the battery positive bus wire to the ground bus wire. The test lamp brilliance may vary from one window to another. 4. Move the test lamp probe from zone 5 to zone 1 along each grid line. - If the test lamp shows full brilliance at both ends of the grid lines. Inspect for an open or poor connection in the ground circuit of the rear window defogger grid. - If the test lamp goes out, test the grid line in at least 2 places (1,3) to eliminate the possibility of bridging the open (2) in the grid line. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 16792 Heated Glass Element: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS BODY CONTROL MODULE (BCM) Rear Defog Relay: When the BCM energizes the RR DEFOG relay, the scan tool will display On. When the BCM de-energizes the RR DEFOG relay, the scan tool will display Off. Rear Defrost Switch: When rear defrost switch is pressed the scan tool displays On. Body Control Module (BCM) HVAC Control Module Body Control Module (BCM) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C - Broken Rear Window Defogger Grid Detection Rear Defogger: Technical Service Bulletins A/C - Broken Rear Window Defogger Grid Detection Bulletin No.: 04-08-48-001B Date: June 28, 2005 INFORMATION Subject: Rear Window Defogger - Broken Heating Grid Detection Method Models: 2006 and Prior Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add the 2006 model year and additional models. Please discard Corporate Bulletin Number 04-08-48-001A (Section 08 - Body and Accessories). The addition of vertical grid lines to the heated back window defogger circuits has made it difficult to detect broken defogger grid lines. In the past, it was a simple matter to use a voltmeter to check the continuity of each grid line in order to locate a non-functional line. Some new design back windows have two vertical grid lines that connect all of the horizontal grid lines together, thereby providing alternate routes for the electrical current to follow. This makes the old test method ineffective. If the vehicle does not have the vertical lines, the old (line-by-line) test methods can be used. Materials Required ^ Permatex(R) Quick Grid, GM P/N 12346001, or equivalent ^ A small ball of fine steel wool Type 00, or ^ Optional - A strip of liquid crystal heat sensitive paper, 51 mm x 305 mm (2 in x 12 in) or similar size (Contact Edmund Scientific at 800-728-6999 for part number CR30723-70 or go to www.scientificsonline.com), or ^ Optional-A portable infrared thermometer, GE-46819, available from Kent-Moore (1-800-345-2233), or equivalent. Correction There are three distinct zones across the back window that must be checked. They are: ^ the driver's side outboard of the two vertical lines ^ the passenger side outboard of the two vertical lines ^ the central zone that falls between the two vertical lines To detect a broken grid line in any of the above three zones and to isolate the exact location of the break, perform the following steps: Caution: ^ Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. ^ Cover the rear shelf area to prevent damage to the interior trim material. 1. Start the engine and turn on the back window defogger. 2. Take the ball of fine steel wool and twist one end to a point. Move the point slowly across each grid line. Be sure to start at the far side of the zone and move it to the opposite side of the zone. When you bridge the grid line break with the steel wool, you will see a small spark. Repeat the test over the same area to be sure you have accurately located the break. Mark the exact location of the grid line break. Repeat this portion of the test for each grid line. If you do not see a spark at any point, it is possible that there are two breaks in the same line and zone. Close visual inspection using a magnifying glass may be the only way to locate breaks in this case. 3. The following are provided as an alternative way to detect a non-functional grid line. If available, use in addition to the steel wool. 3.1. Method using liquid crystal heat sensitive paper: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C - Broken Rear Window Defogger Grid Detection > Page 16797 Important: The first part of the test must be completed quickly before the entire surface of the back window becomes warm. 3.1.1. From outside the vehicle, place the heat sensitive paper (dull surface in contact with the glass) against the top driver side grid line. Start the engine and turn on the back window defogger. A distinct color change will take place at each conductive grid line. Repeat for the bottom grid lines until they have all been checked in the driver side zone. 3.1.2. Repeat the process for the passenger side and center area zones. 3.1.3. If no color change is noted for a grid line, place a crayon or china marker check mark beside it. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 3.2. Method using portable infrared thermometer: 3.2.1. Start the engine and turn on the rear back window defogger. 3.2.2. From inside the vehicle, start at the top driver side grid line and slowly run the portable infrared thermometer vertically down the rear window contacting each grid line. You should be able to see a district variation in temperature readings. 3.2.3. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 3.2.4. Repeat the process for the passenger side and center area zones. 4. Use Permatex(R) Quick Grid, GM P/N 12346001, or equivalent, to repair each broken grid line. Follow the manufacturer's instructions. 5. Wait 24 hours before turning the defogger on, or the repair can be fast cured using a heat gun, 260°C - 371°C (500°F - 700°F). Hold the heat gun within 25 - 51 mm (1-2 in) from the repair point for 2 to 3 minutes. 6. Recheck the grid line with the heat sensitive paper or portable infrared thermometer to ensure that the line is now functional and that the repair was successful. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions Rear Defogger: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16800 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16801 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16802 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16803 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16804 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16805 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16806 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16807 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16808 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16809 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16810 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16811 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16812 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16813 Rear Defogger: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16814 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16815 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16816 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16817 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16818 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16819 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16820 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16821 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16822 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16823 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16824 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16825 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16826 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16827 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16828 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16829 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16830 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16831 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16832 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16833 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16834 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16835 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16836 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16837 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16838 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16839 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16840 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16841 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16842 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16843 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16844 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16845 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16846 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 16847 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16853 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16854 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16855 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16856 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16857 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16858 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16859 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16860 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16861 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16862 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16863 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16864 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16865 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16866 Power Window Switch: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16867 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16868 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16869 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16870 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16871 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16872 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16873 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16874 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16875 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16876 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16877 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16878 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16879 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16880 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16881 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16882 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16883 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16884 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16885 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16886 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16887 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16888 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16889 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16890 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16891 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16892 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16893 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16894 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16895 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16896 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16897 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16898 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16899 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16900 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16901 Power Window Switch: Connector Views Window Switch - LR (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16902 Window Switch - RR (Crew Cab Only) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16903 Window Switch - RR (Crew Cab Only) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Rear Door Power Window Switch: Service and Repair Power Window Switch Replacement - Rear Door POWER WINDOW SWITCH REPLACEMENT - REAR DOOR REMOVAL PROCEDURE 1. Use a small flat-bladed tool in order to carefully pry the door power window switch from the door trim panel. 2. Disconnect the electrical connector from the switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the switch. 2. Install the switch to the door trim panel by pressing the switch into place until fully seated. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Rear Door > Page 16906 Power Window Switch: Service and Repair Switch Replacement - Door Lock and Side Window Driver SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - DRIVER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Rear Door > Page 16907 INSTALLATION PROCEDURE 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Rear Door > Page 16908 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Rear Door > Page 16909 Power Window Switch: Service and Repair Switch Replacement - Door Lock and Side Window Passenger SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - PASSENGER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Rear Door > Page 16910 INSTALLATION PROCEDURE 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair Rear Door Window Motor: Service and Repair Window Regulator Motor Replacement - Rear Door Removal Procedure 1. Raise the window. If the window motor is inoperable, remove the window to gain access to the window motor retaining screws. Refer to Window Replacement - Rear Door. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the door speaker. 5. Support the window. 6. Disconnect the wiring harness from the window regulator motor. 7. Remove the 3 bolts from the window motor located on the front side of the motor. Important: Do not allow the cable gear come out of the housing. A failure will result with the cable coming off the spool. 8. Separate the motor from the cable housing by wiggling the window motor. Observe the orientation of the window motor. 9. Remove the motor from the window regulator assembly. Installation Procedure 1. Install the motor to the cable housing by wiggling motor into place. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 3 bolts to the window motor. Tighten the bolts to 5 N.m (44 lb in). 3. Install the window, if removed. 4. Connect the wiring harness to the window regulator motor. 5. Remove the window support. 6. Connect the wire connector to the switch to inspect the operation of the window. 7. Install the speaker. 8. Install the water deflector. 9. Install the door trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Truck Zoning TRUCK ZONING Truck Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The table explains the numbering system. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16920 Electrical Symbols ELECTRICAL SYMBOLS Electrical Symbols Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16921 Electrical Symbols Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16922 Electrical Symbols Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16923 Electrical Symbols Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16924 Electrical Symbols Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16925 Electrical Symbols Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16926 Electrical Symbols Part 8 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16927 Electrical Symbols Part 9 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16928 Electrical Symbols Part 10 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16929 Electrical Symbols Part 11 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16930 Electrical Symbols Part 12 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16931 Electrical Symbols Part 13 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16932 Electrical Symbols Part 14 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16933 Power Window Switch: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the Service Data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: - Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16934 High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16935 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors USING CONNECTOR TEST ADAPTERS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16936 Refer to the table as a guide in selecting the correct test adapter for frontprobing connectors: Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16937 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 msRECORD and emits an audible tone (beep). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16938 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS TOOLS REQUIRED - J 35616-C GM-Approved Terminal Test Kit - J 38125-D Terminal Repair Kit - J 42675 Flat-Wire Probe Adapter Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through - This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. Testing For Proper Terminal Contact It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-D or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-D, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16939 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16940 TOOLS REQUIRED J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach 1 lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16941 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly, Refer to Wiring Repairs. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16942 Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Micro .64 Connectors MICRO .64 CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE Follow the steps below in order to remove terminals from Micro 64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16943 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. 5. If the connector has a nose piece, use a small flat-blade tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. IMPORTANT: Be careful not to angle or rock the J 38125-13A tool when inserting it into the connector or the tool may break. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16944 7. Insert the J 38125-13A (GM P/N 12031876-1) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the Terminal Repair Kit to ensure that the correct release tool is used. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. REPAIR PROCEDURE Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16945 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16946 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TOOLS REQUIRED J 38125-D Terminal Repair Kit REMOVAL PROCEDURE There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2)has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16947 Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16948 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16949 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. REPAIR PROCEDURE The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16950 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. REPLACEMENT PROCEDURE After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS TOOLS REQUIRED J 38125-D Terminal Repair Kit Use the following repair procedures in order to repair the following: - Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16951 Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16952 circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: - Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-D. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16953 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-D Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-D contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-D also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16954 SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-D. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: - The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-D Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-D. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16955 - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-D in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-D if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16956 Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. TOOLS REQUIRED J 38125-D Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-D in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16957 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16958 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-D Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or a provide good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16959 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-8 (12085115) crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-8 (12085115) until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate Service Data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. 9. Tape the diode to the harness or connector using electrical tape. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16960 IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Control Module References Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16961 Control Module References Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16962 Control Module References Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16963 Control Module References Part 3 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16964 Control Module References Part 4 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16965 Control Module References Part 5 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16966 Control Module References Part 6 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16967 Control Module References Part 7 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16968 Power Window Switch: Connector Views Window Switch - LR (Crew Cab Only) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16969 Window Switch - RR (Crew Cab Only) Part 1 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 16970 Window Switch - RR (Crew Cab Only) Part 2 Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Rear Door Power Window Switch: Service and Repair Power Window Switch Replacement - Rear Door POWER WINDOW SWITCH REPLACEMENT - REAR DOOR REMOVAL PROCEDURE 1. Use a small flat-bladed tool in order to carefully pry the door power window switch from the door trim panel. 2. Disconnect the electrical connector from the switch. INSTALLATION PROCEDURE 1. Connect the electrical connector to the switch. 2. Install the switch to the door trim panel by pressing the switch into place until fully seated. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Rear Door > Page 16973 Power Window Switch: Service and Repair Switch Replacement - Door Lock and Side Window Driver SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - DRIVER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Rear Door > Page 16974 INSTALLATION PROCEDURE 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Rear Door > Page 16975 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Rear Door > Page 16976 Power Window Switch: Service and Repair Switch Replacement - Door Lock and Side Window Passenger SWITCH REPLACEMENT - DOOR LOCK AND SIDE WINDOW - PASSENGER REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors. 3. Remove the screw that retains the switch panel bezel (1) from the front door panel. 4. Remove the switch panel bezel from the door panel using a flat-bladed tool. 5. Using a wide plastic flat-bladed tool, release the retaining clips on both sides of the door module. 6. Remove the door module from the switch panel bezel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement - Rear Door > Page 16977 INSTALLATION PROCEDURE 1. Install the door module into the switch panel bezel until it snaps into place. 2. Install the switch panel bezel and module to the door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the switch panel bezel (1) to the front door panel. Tighten Tighten the screw to 2 N.m (18 lb in). 4. Connect the electrical connectors. 5. Install the front door trim panel. 6. If equipped with camper mirrors program the door module. Refer to Service Programming System (SPS) in Programming. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: Customer Interest A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 16987 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 16988 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 16989 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 16995 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 16996 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 16997 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Other Service Bulletins for Back Window Glass: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Page 17007 Back Window Glass: Service and Repair Rear Window Replacement (Pickup) Removal Procedure Tools Required * J 24402-A Cold Knife Glass Sealant Remover * J 39040 Quarter Window Remover * Urethane Adhesive Kit GM P/N 12346392 or Equivalent * Isopropyl Alcohol or Equivalent * Cartridge-type Caulking Gun * Commercial-type Utility Knife * Razor Blade Scraper * Suction Cups * Plastic Paddle Caution: If a window is cracked but still intact, crisscross the window with masking tape in order to reduce the risk of damage or personal injury. Important: Before cutting out a window, apply a double layer of masking tape around the perimeter of the painted surfaces and interior trim. 1. Remove the window lower garnish molding. 2. Remove both rear seat headrests (extended cab). 3. Lower rear seat back. Caution: If broken glass falls into the defroster outlets, it can be blown into the passenger compartment and cause personal injury. 4. Cover to protect the following parts from broken glass: 1. Upper dash pad 2. Defroster outlets and A/C outlets 3. Seats and carpeting Caution: When working with any type of glass or sheet metal with exposed or rough edges, wear approved safety glasses and gloves in order to reduce the chance of personal injury. Important: Keep the cutting edge of the tool against the window. 5. This will allow the urethane adhesive to be separated from the window. * Leave a base of urethane on the pinchweld flange. * The only suitable lubrication is clear water. * Use J 24402-A, J 39040 or equivalent in order to remove the window. 6. Open the window, if equipped. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Page 17008 7. With the aid of an assistant, remove the window from the opening. Installation Procedure 1. Install a stationary window into the opening. 2. Install the window lower garnish molding. 3. Install both rear seat headrests (extended cab). 4. Raise the rear seat back. 5. Remove the double layer of masking tape around the perimeter of the painted surfaces and interior trim. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Corner Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Front Corner Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel Front Door Window Glass Weatherstrip: Service and Repair Door Window Channel Window Run Channel Replacement - Front Door Removal Procedure 1. Remove the window. 2. Remove the window glass weatherstrip. 3. Remove the window run channel bolts. 4. Remove the front and the rear window run channels from the door. Installation Procedure 1. Install the front and the rear window run channels to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the front and the rear window run channel bolts. 1. Tighten the front bolt to 9 N.m (80 lb in). 2. Tighten the rear bolt to 9 N.m (80 lb in). 3. Install the window glass weatherstrip. 4. Install the window. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 17018 Front Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Front Door Window Removal Procedure 1. Remove the door trim panel. 2. Remove the water deflector. 3. Remove the window. 4. Remove the screws. 5. Pull the weatherstrip from the following locations: * The front of the glass run channel * The top of the window frame flange * The rear of the glass run channel 6. Remove the weatherstrip from the door. Installation Procedure 1. Install the weatherstrip to the following locations: * The front of the glass run channel * The top of the window frame flange * The rear of the glass run channel Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts. Tighten to 6 N.m (53 lb in). 3. Install the window. 4. Install the water deflector. 5. Install the door trim panel. 6. Inspect operation of window. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 17019 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Front Door Window Belt Outer - Front Removal Procedure Important: The outer belt sealing strip seals between the inner and outer door panels and the window at the belt line. The outer sealing strip is replaceable. Do not remove the inner sealing strip, because the strip is attached to the glass run channel. 1. Lower the window. 2. Remove the outside mirror. 3. Remove the outer sealing strip from the door, lifting up on the forward end in order to unhook the rear of the strip from the window run channel. Installation Procedure 1. Hook the rear end of the sealing strip into the window run channel. Lower and press the strip into place. 2. Install the outside mirror. 3. Raise the window. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Quarter Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Technical Service Bulletins > Page 17024 Quarter Window Glass: Service and Repair Quarter Window Replacement Tools Required * J 24402-A Glass Sealant Cold Knife Remover * J 39032 Stationary Glass Removal Tool * Urethane Adhesive Kit GM P/N 12346392 or Equivalent * Isopropyl Alcohol or Equivalent * Cartridge-type Caulking Gun * Commercial-type Utility Knife * Razor Blade Scraper * Suction Cups * Plastic Paddle Removal Procedure Caution: If a window is cracked but still intact, crisscross the window with masking tape in order to reduce the risk of damage or personal injury. Important: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 1. Open the side access door. 2. Remove the side access door trim, if equipped. Caution: When working with any type of glass or sheet metal with exposed or rough edges, wear approved safety glasses and gloves in order to reduce the chance of personal injury. Important: Keep the cutting edge of the tool against the window. This will allow the urethane adhesive to be separated from the window. 3. If the original reveal molding on the window is damaged it must be replaced, if equipped. * Leave a base of urethane on the pinchweld flange. * The only suitable lubrication is clear water. * Use J 24402-A, J 39032 or equivalent in order to remove the window. 4. With the aid of an assistant, remove the window from the opening. Installation Procedure 1. Install a stationary window into the opening. 2. Install the side access door trim, if equipped. 3. Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior trim. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Technical Service Bulletins > Page 17025 4. Close the side access door. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Weatherstrip Rear Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Rear Door Window Removal Procedure 1. Remove the window. 2. Pull the weatherstrip from the front window run channel. 3. Pull the weatherstrip from the rear window run channel. 4. Pull the weatherstrip from the window frame flange. Installation Procedure 1. Align the weatherstrip in the window frame flange. 2. Press the weatherstrip into the window frame flange until fully seated. 3. Press the weatherstrip into the rear window run channel until fully seated. 4. Press the weatherstrip into the front window run channel until fully seated. 5. Install the window. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Weatherstrip > Page 17031 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Rear Door Window Belt Outer Removal Procedure Important: The outer belt sealing strip seals between the inner and outer door panels and the window at the belt line. The outer sealing strip is replaceable. Do not remove the inner sealing strip, because the strip is attached to the glass run channel. 1. Lower the window. 2. Remove the outer sealing strip from the door. Installation Procedure 1. Align the sealing strip in place. Lower and press the strip into place. 2. Raise the window. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Handle > Component Information > Service and Repair Window Handle: Service and Repair Window Handle Replacement Tools Required J 9886-01 Door Handle Clip Remover Removal Procedure 1. Open the door. 2. Remove the window crank handle using the J 9886-01. Be sure to retain the retainer clip on the back side of the handle. Installation Procedure 1. Install the window crank handle by pushing the handle into place. Ensure that the retainer engages. 2. Inspect the operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement (Manual) Front Door Window Regulator: Service and Repair Door Window Regulator Replacement (Manual) Window Regulator Replacement - Front Door Removal Procedure 1. Raise and support the window glass. 2. Remove the trim panel. 3. Remove the water deflector. 4. Remove the 2 bolts that hold the window to the regulator. 5. Remove the bolts from the window regulator. 6. Remove the window regulator assembly from the door by folding both sides together. Installation Procedure 1. Install the regulator to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the window regulator. Tighten the bolts to 9 N.m (80 lb in). 3. Align the window glass to the regulator. 4. Install the bolts that hold the window to the regulator. Tighten the bolts to 9 N.m (80 lb in). 5. Install the water deflector. 6. Install the trim panel. 7. Lower the window. Inspect the operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement (Manual) > Page 17040 Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Motor Replacement Window Regulator Motor Replacement - Front Door Removal Procedure 1. Raise the window. If the window motor is inoperable, remove the window to gain access to the window motor retaining screws. Refer to Window Replacement - Front Door. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the door speaker. 5. Support the window. 6. Disconnect the wiring harness from the window regulator motor. 7. Remove the 3 bolts (1) from the window motor. Important: Do not allow the cable gear to come out of the housing. A failure will result with the cable coming off the spool. 8. Separate the motor from the cable housing by wiggling the window motor. Observe the orientation of the window motor. 9. Remove the motor from the door regulator assembly. Installation Procedure 1. Install the motor to the cable housing by wiggling it into place. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 3 bolts(1) to the window motor. Tighten Tighten the bolts to 5 N.m (44 lb in). 3. Install the window, if removed. 4. Connect the wiring harness to the window regulator motor. 5. Remove the window support. 6. Connect the wire connector to the switch to inspect the operation of the window. After inspection disconnect the wiring harness and continue the installation. 7. Install the speaker. 8. Install the water deflector. 9. Install the door trim panel. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair Window Regulator Replacement - Rear Door Removal Procedure 1. Raise and support the window glass. 2. Remove the trim panel. 3. Remove the water deflector. 4. Remove the 2 bolts that hold the window to the regulator. 5. Remove the bolts from the window regulator. 6. Remove the window regulator assembly from the door by folding both sides together. Installation Procedure 1. Install the regulator to the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the window regulator. Tighten the bolts to 9 N.m (80 lb in). 3. Align the window glass to the regulator. 4. Install the bolts that hold the window to the regulator. Tighten the bolts to 9 N.m (80 lb in). 5. Install the water deflector. 6. Install the trim panel. 7. Lower the window. Inspect the operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair Windshield Moulding / Trim: Service and Repair Stationary Window Reveal Molding Repair Stationary Window Reveal Molding Repair Removal Procedure Caution: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. Important: The window reveal molding fills the cavity between the body and window. If the reveal molding is stretched or damaged, it cannot be reused and it must be replaced. 1. Lift up on the loose area of the reveal molding. 2. Clean the top edge of the window surface and the reveal molding with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint-free cloth. Installation Procedure Caution: Refer to Window Retention Caution in Service Precautions. 1. Verify all primers and urethane adhesive are within expiration dates. Important: Use care when applying the prep, clear #1, to the window. This primer dries almost instantly, and may stain the viewing area of the window if not applied evenly. 2. Use a new dauber in order to apply glass prep, clear #1, to the channel area approximately 13 mm (1/2 in) to the upper edge of the window. 3. Wipe the glass primed area immediately with a clean lint-free cloth. 4. Shake the glass primer, black #2, for at least 1 minute. 5. Use a new dauber in order to apply glass primer, black #2, to the top edge of the window. 6. Apply a small bead of urethane adhesive (2) between the window (1) and the pinch-weld. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair > Page 17049 7. Reinstall the window reveal molding. 1. Start from the loose area and hand-press the reveal molding into place over the edge of the window. 2. Run warm water over the reveal molding in order to speed the setup time of the urethane adhesive. 3. Tape should be applied in order to retain the reveal molding to the window. This will maintain a flush fit with the body. 4. The tape is to be removed after 6 hours. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair > Page 17050 Windshield Moulding / Trim: Service and Repair Windshield Side Reveal Molding Replacement Windshield Side Reveal Molding Replacement Removal Procedure 1. Pull back the front door sealing weatherstrip (1) to expose the windshield reveal molding screws. 2. Remove the screws from the windshield reveal molding. 3. Remove the windshield reveal molding from the windshield pillar. Installation Procedure 1. Install the windshield reveal molding to the windshield pillar. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the windshield reveal molding. Tighten the screws to the windshield reveal molding to 2 N.m (18 lb in). 3. Install the front door sealing weatherstrip (1) to the pinch-weld. 4. Close the door. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair > Page 17051 Windshield Moulding / Trim: Service and Repair Windshield Upper Reveal Molding Replacement Windshield Upper Reveal Molding Replacement Tools Required * Urethane Adhesive Kit GM P/N 12346392 or Equivalent * Isopropyl Alcohol or Equivalent * Cartridge-type Caulking Gun * Plastic Paddle Removal Procedure 1. Remove both right and left sides of the reveal molding. Caution: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. Important: The windshield reveal molding fills the cavities between the body and windshield. If the reveal molding is stretched or damaged it and cannot be reused it must be replaced. 2. Remove the upper windshield reveal molding. 1. Use a flat-bladed tool in order to carefully pry the end of the upper reveal molding out about 76 mm (3 in). 2. Grasp the corner of the windshield reveal molding by hand or use a suitable tool to slowly pull the reveal molding away from the windshield. 3. If the windshield reveal molding will not release, use a utility knife to aid in the releasing of the molding. Installation Procedure 1. Clean the top edge of the windshield surface with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint - free cloth. 2. The new reveal molding should be fitted to the windshield prior to installation. Caution: Refer to Window Retention Caution in Service Precautions. 3. Verify all primers and urethane adhesive are within expiration dates. Important: Use care when applying the prep (clear #1) to the windshield. This primer dries almost instantly, and may stain the viewing area of the windshield if not applied evenly. 4. Use a new dauber in order to apply glass prep (clear #1) to the channel area approximately 13 mm (1/2 in) to the upper edge of the windshield. 5. Wipe the glass primed area immediately with a clean lint-free cloth. 6. Shake the glass primer (black #2) for at least one minute. Using a new dauber in order to apply glass primer (black #2) to the top edge of the windshield. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair > Page 17052 7. Apply a small bead of urethane adhesive (2) between the windshield (1) and the pinchweld. 8. Install the upper reveal molding. 1. Start from the center and hand-press the reveal molding into place over the edge of the windshield. 2. Install both right and left sides of the reveal molding. 3. Run warm water over the reveal molding in order to speed the setup time of the urethane adhesive. Tape should be applied in order to retain the reveal molding to the windshield, this will maintain a flush fit with the body. The tape is to be removed after 6 hours. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Windshield Washer Reservoir Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 17058 Washer Fluid Level Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 17059 Washer Fluid Level Switch: Service and Repair WASHER SOLVENT CONTAINER LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the washer solvent container. 2. Using a small flat-bladed tool, remove the washer solvent container level sensor (1) and seal (2) from the container. INSTALLATION PROCEDURE 1. Position the washer solvent container level sensor (1) and the seal (2) to the container by pressing in until fully seated. 2. Install the washer solvent container. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Windshield Washer Reservoir Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 17063 Washer Fluid Level Switch Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 17064 Washer Fluid Level Switch: Service and Repair WASHER SOLVENT CONTAINER LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the washer solvent container. 2. Using a small flat-bladed tool, remove the washer solvent container level sensor (1) and seal (2) from the container. INSTALLATION PROCEDURE 1. Position the washer solvent container level sensor (1) and the seal (2) to the container by pressing in until fully seated. 2. Install the washer solvent container. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams Windshield Washer Fluid Pump Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Page 17068 Windshield Washer Pump: Service and Repair WASHER PUMP REPLACEMENT REMOVAL PROCEDURE 1. Remove the washer solvent container. 2. Remove the washer pumps from the reservoir. INSTALLATION PROCEDURE 1. Install the washer pumps into the reservoir. 2. Install the washer solvent container. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair Windshield Washer Reservoir: Service and Repair WASHER PUMP/RESERVOIR REPLACEMENT REMOVAL PROCEDURE 1. Remove the battery and battery tray from the vehicle. 2. Remove the inner wheel housing from the vehicle. 3. Disconnect the electrical connector from the washer pump. 4. Disconnect the electrical connector from the washer solvent level sensor. 5. Disconnect the washer hose from the washer pump. 6. Remove the upper bolt from the washer solvent container. 7. Remove the lower bolts from the washer solvent container. 8. Remove the washer solvent container from the vehicle. INSTALLATION PROCEDURE Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Page 17072 1. Install the washer solvent container into the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the lower bolts. Tighten Tighten the bolts to 9 N.m (80 lb in). 3. Install the upper bolt. Tighten Tighten the bolt to 9 N.m (80 lb in). 4. Connect the electrical connector to the washer pump. 5. Connect the electrical connector to the washer solvent level sensor. 6. Connect the washer hose to the washer pump. 7. Install the inner wheel housing. 8. Install the battery and battery tray. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Testing and Inspection Wiper Arm: Testing and Inspection WIPER ARM TIP PRESSURE CHECK 1. Run the wiper arms to the mid-wipe position. 2. Remove the wiper blades from the wiper arms. 3. Attach a scale to the end of the wiper arm and measure the force required to lift the wiper arm perpendicular to the windshield to normal working height with the blade attached. 4. Replace the wiper arm if the measurement is not within the specification. Tip Pressure Driver Side - 8.1-9.5 Newtons (29- 34 Ounces) - Passenger Side - 5.8-7.0 Newtons (21- 25 Ounces) Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Testing and Inspection > Page 17076 Wiper Arm: Service and Repair WIPER ARM REPLACEMENT REMOVAL PROCEDURE 1. Mark the position of the wiper blade on the windshield with a suitable marker or a piece of masking tape. 2. Disconnect the washer hose. 3. Remove the cover from the nut on the wiper arm. 4. Remove the nut from the wiper arm. IMPORTANT: Use a battery terminal puller to remove the wiper arm from the drive shaft. 5. Remove the wiper arm from the drive shaft. 6. Clean the knurls of the drive shaft with a wire brush. INSTALLATION PROCEDURE 1. Position the wiper arm so that the wiper blade aligns with the mark made on the windshield before removal. 2. Install the wiper arm onto the drive shaft. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the nut on the drive shaft. Tighten Tighten the nut to 30 N.m (22 lb ft). 4. Install the cover on the nut. 5. Connect the washer hose. 6. Clean the locating mark or masking tape from the windshield. 7. Operate the wipers and inspect for proper operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Glass/Body - Windshield Wiper Performance Wiper Blade: Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Glass/Body - Windshield Wiper Performance > Page 17081 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 17082 Wiper Blade: Testing and Inspection WIPER BLADE ELEMENT CHECK 1. Remove the wiper blades from the wiper arms. 2. Look down the length of the blade element. 3. Replace the wiper blade element if the rubber element which contacts the glass is not on the centerline of the blade +/-15 degrees. 4. Install the wiper blades on the wiper arms. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement Wiper Blade: Service and Repair Wiper Arm Blade Replacement WIPER ARM BLADE REPLACEMENT REMOVAL PROCEDURE 1. Turn the ignition switch to the ACCY position. 2. Set the wiper switch to the PULSE position. 3. Turn the ignition OFF when the wipers are in the innerwipe position and not moving. 4. Push in the button of the wiper blade clip and remove the wiper blade from the inside radius of the wiper arm. 5. Bring the wiper arm out through the opening in the wiper blade. INSTALLATION PROCEDURE 1. Insert the hook of the wiper arm through the opening in the wiper blade. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement > Page 17085 2. Position the wiper blade pivot in the inside radius of the wiper arm hook. 3. Pull the wiper blade pivot into the wiper arm hook until the pivot locks into the hook. 4. Operate the wipers and inspect for proper operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement > Page 17086 Wiper Blade: Service and Repair Wiper Blade Element Replacement WIPER BLADE ELEMENT REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Replace the wiper blade element if it is removed from the wiper blade. 1. Remove the wiper blade from the wiper arm. 2. Remove the bottom claws (2) of the wiper blade (1) from the notches in the wiper blade element (3). 3. Pull the wiper blade element (3) out through the wiper blade claws (2). INSTALLATION PROCEDURE IMPORTANT: Keep the wiper blade claws in the rubber claw channel of the wiper blade element. Do not allow the claws of the wiper blade to contact the metal spline of the wiper blade element. 1. Insert the open end of the wiper blade element (3) into the bottom claws of the wiper blade (2). 2. Guide the wiper blade element (3) through the wiper blade (1) claw sets. 3. Engage the bottom claw (2) of the wiper blade (1) into the notches in wiper blade element (3). 4. Install the wiper blade onto the wiper arm. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement > Page 17087 Wiper Blade: Service and Repair Blade Element Cleaning BLADE ELEMENT CLEANING 1. Lift the wiper blade assemblies off of the windshield glass. 2. Clean the wiper blade element with a clean cloth saturated with full strength washer solution. 3. Rinse the wiper blade assemblies with water. 4. Place the wiper blade assemblies back onto the windshield glass. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair Wiper Gear Box: Service and Repair WIPER TRANSMISSION REPLACEMENT TOOLS REQUIRED - J 39232 Wiper Transmission Separator - J 39529 Wiper Transmission Installer REMOVAL PROCEDURE 1. Remove the wiper arms. 2. Remove the air inlet grille panel. 3. Remove the 4 bolts and the reinforcement panel. 4. Disconnect the electrical connector from the wiper motor. 5. Remove the 2 bolts from the wiper transmission assembly. 6. Remove the wiper transmission assembly from the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair > Page 17091 7. Remove the drive link from the wiper motor crank arm with the J 39232. 8. Remove the 2 bolts retaining the wiper motor. 9. Remove the wiper motor from the wiper transmission assembly. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the wiper motor onto the wiper transmission assembly with the 2 bolts. Tighten Tighten the 2 bolts to 8 N.m (71 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair > Page 17092 2. Install the drive link onto the wiper motor crank arm with the J 39529. 3. Install the wiper transmission assembly on the vehicle with the 2 bolts. Tighten Tighten the 2 bolts to 9 N.m (80 lb in). 4. Connect the electrical connector to the wiper motor. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair > Page 17093 5. Install the reinforcement panel with the 4 bolts. Tighten Tighten the 4 bolts to 9 N.m (80 lb in). 6. Install the air inlet grille panel. 7. Install the wiper arms. 8. Operate the wipers and inspect for proper operation. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations Left Rear Underhood - Front Of Dash Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Connector Views Windshield Wiper Motor Module Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 17099 Wiper Motor: Service and Repair WIPER MOTOR REPLACEMENT TOOLS REQUIRED - J 39232 Wiper Transmission Separator - J 39529 Wiper Transmission Installer REMOVAL PROCEDURE 1. Remove the wiper arms. 2. Remove the air inlet grille panel. 3. Remove the 4 bolts and the reinforcement panel. 4. Disconnect the electrical connector from the wiper motor. 5. Remove the 2 bolts from the wiper transmission assembly. 6. Remove the wiper transmission assembly from the vehicle. Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 17100 7. Remove the drive link from the wiper motor crank arm with the J 39232. 8. Remove the 2 bolts retaining the wiper motor. 9. Remove the wiper motor from the wiper transmission assembly. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the wiper motor onto the wiper transmission assembly with the 2 bolts. Tighten Tighten the 2 bolts to 8 N.m (71 lb in). Chevrolet Silverado 2500 4wd Workshop Manual (V8-6.6L DSL Turbo VIN 2 (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 17101 2. Install the drive link onto the wiper motor crank arm with the J 39529. 3. Install the wiper transmission assembly on the vehicle with the 2 bolts. Tighten Tighten the 2 bolts to 9 N.m (80 lb in). 4. Connect the electrical connector to the wiper motor.